RGR 570 Ext Crew 2015-2016

2015 - 2016 RANGER ETX / 570 2-SEAT
2015 - 2016 RANGER 570 CREW

FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer® technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed October 2015 (PN 9926806 R03)
© Copyright 2015 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information
presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or
inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
SAFETY WARNINGS
Throughout this manual, important information is brought to your attention by the following symbols:
WARNING
SAFETY ALERT WARNING indicates a potential hazard that may result in severe injury or death to the operator,
bystander or person(s) inspecting or servicing the vehicle.
CAUTION
SAFETY ALERT CAUTION indicates a potential hazard that may result in minor personal injury or damage to the
vehicle.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle damage or property damage.
NOTE
NOTE provides key information by clarifying instructions.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly and inspection of components.
TRADEMARKS
POLARIS ACKNOWLEDGES THE FOLLOWING PRODUCTS MENTIONED IN THIS MANUAL:
Loctite, Registered Trademark of the Loctite Corporation
Nyogel, Trademark of Wm. F. Nye Co.
Fluke, Registered Trademark of John Fluke Mfg. Co.
Mity-Vac, Registered Trademark of Neward Enterprises, Inc.
Torx, Registered Trademark of Textron
Hilliard, Trademark of the Hilliard Corporation
Warn, Trademark of Warn Industries
FOX, Registered Trademark of FOX RACING SHOX
RydeFX, Registered Trademark of ArvinMeritor
Some Polaris factory publications can be downloaded from www.polarisindustries.com, purchased from
www.purepolaris.com or by contacting the nearest Polaris dealer.
REVISION INDEX: 2015 - 2016 RANGER 4X4
REV DATE CHANGES

R01 10/01/2015 Initial release
• Revised cylinder head bolt torque to be based on bolt color instead of model
R02 12/30/2015 year
• Reworded Oil Change procedure
R03 06/10/2016 Parking Brake Service Added

2015-2016 RANGERETX/5702-SEAT 2015-
2016RANGER570CREW
Service Manual
Chapter Summary
CHAPTER 1: GENERAL INFORMATION

CHAPTER 2: MAINTENANCE
CHAPTER 3: ENGINE / COOLING SYSTEM
CHAPTER 4: FUEL SYSTEM
CHAPTER 5: PVT SYSTEM
CHAPTER 6: TRANSMISSION
CHAPTER 7: FINAL DRIVE
CHAPTER 8: STEERING / SUSPENSION
CHAPTER 9: BRAKE SYSTEM
CHAPTER 10: BODY / FRAME
CHAPTER 11: ELECTRICAL
GENERAL INFORMATION
CHAPTER 1 1
GENERAL INFORMATION
VEHICLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
MODEL NUMBER DESIGNATION (2015 +) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
VIN / ENGINE NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
MODEL: 2015 RANGER ETX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2015 RANGER ETX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.5
MODEL: 2015 RANGER 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
2015 RANGER 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
MODEL: 2015 RANGER 570 CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
2015 RANGER 570 CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.9
MODEL: 2016 RANGER ETX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.10
2016 RANGER ETX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.11
MODEL: 2016 RANGER 570 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.12
2016 RANGER 570 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.13
MODEL: 2016 RANGER 570 2X4 (INTL.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.14
2016 RANGER 2X4 (INTL.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.15
MODEL: 2016 RANGER 570 CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16
2016 RANGER 570 CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.16
MISC. SPECIFICATIONS AND CHARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18
PUBLICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.18
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.19
REPLACEMENT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.20
MASTER SPECIAL TOOLS TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.21
MASTER TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.30
CLUTCHING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.33
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.34
STANDARD BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.35
METRIC BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.35
SAE TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.36
METRIC TAP / DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.37
DECIMAL EQUIVALENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.38
9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual
© Copyright Polaris Industries Inc. 1.1
GENERAL INFORMATION
VEHICLE INFORMATION
MODEL NUMBER DESIGNATION (2015 +)
Example: R15RUE57AC
GROUP MODEL YEAR MAKE / CHASSIS CODE ENGINE CODE REGION OPTION
1st 2nd 3rd 4th* 5th* 6th* 7th* 8th* 9th 10th**
R 1 5 R U E 5 7 A C
* = digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
** = 10th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 10th digit are used in model number only. They are not used with the 17 digit VIN.
Digits 1 through 8 determine Digital Wrench calibration.
VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+)

Example: 4XARUE573FG000000
VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

ENGINE MODIFIER
MFG. LOCATION
MODEL YEAR *
CHECK DIGIT
ENGINE SIZE
DRIVELINE
MODIFIER
CHASSIS
CHASSIS
WORLD MFG. ID
INDIVIDUAL SERIAL NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
4 X A R U E 5 7 3 F G 0 0 0 0 0 0
* Model Year: A = 2010; B = 2011; C = 2012; D = 2013; E = 2014; F = 2015; G= 2016; H=2017; J=2018
1.2 © Copyright Polaris Industries Inc.
GENERAL INFORMATION
VIN / ENGINE NUMBER LOCATION

Whenever corresponding about a Polaris RANGER utility vehicle, be sure to refer to the Vehicle Identification Number
(VIN) and the engine model and serial number.
1
The VIN q can be found stamped on the upper frame rail on the rear LH side of the vehicle below the cargo box.
The engine model and serial number w can be found on a decal applied to the engine’s magneto cover.
GENERAL INFORMATION
GENERAL SPECIFICATIONS
MODEL: 2015 RANGER ETX
MODEL NUMBER:
R15RMA32AA, AJ, FA
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
Height 73″ / 185 cm
Wheel Base 73″ / 185 cm
Ground Clearance 10″ / 25.4 cm
Turning Radius 150″ / 381 cm
Dry Weight 1145 lbs. / 474 kg
Cargo Box Capacity 500 lbs. / 227 kg
Cargo Box Dimensions L- 42″ x W-32″ x H-11.5″
(inside dimensions) (107 x 81 x 29 cm)
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)
Towing Capacity 1500 lbs. / 680.4kg
Hitch Tongue Capacity 150 lbs. / 68 kg
GENERAL INFORMATION
2015 RANGER ETX ELECTRICAL
Model Specifications
Relays EFI / Chassis / Fan / Fuel Pump /
Headlight / EPS (EPS model
1
only)
ENGINE Circuit Breaker Fan Motor: 20 Amp
Domestic Single Cyl., Liquid
Platform Fuses Brake Light: 5 Amp
Cooled, 4–Stroke, DOHC
EFI: 20 Amp
Engine Displacement 325cc Fuel Pump: 10 Amp
Bore & Stroke 78 x 68 mm EPS (EPS model only): 20 Amp
Accessory: 20 Amp
Compression Ratio 11.5:1 Drive: 10 Amp
Engine Idle Speed 1250 ±50 RPM Lights: 20 Amp
Engine Max Speed 8500 RPM DRIVETRAIN
Valve Clearance (Intake) 0.005±0.002″ (0.125±0.05 mm) Transmission Type Polaris Automatic PVT
Valve Clearance Shift Type In Line Shift - P/ H / L / N / R
0.0014-0.002″ (0.35±0.05 mm)
(Exhaust) Front Gearcase Lubricant Demand Drive
Oil Requirements PS4 synthetic Requirement 6.7–7.6 oz. (200–225 ml)
Oil Capacity 1.75 qts. (1.61 L) Transmission Lubricant Full Synthetic AGL
Requirement 33.8 oz. (1000 ml)
Coolant Capacity 120 Oz (3.5 L)
STEERING / SUSPENSION
FUEL SYSTEM
Toe Out 1/8 − 1/4″ (3.20 − 6.35 mm)
Type Bosch ME17 EFI
Front Suspension Strut / A-arm
Fuel Delivery Electronic Fuel Pump (in-tank)
Front Travel 9″ (20.3 cm)
Fuel Pressure 58 ± 2 PSI (400 ± 14 kPa)
Rear Suspension Independent (IRS)
Fuel Capacity / 8.8 gal. (33.3 L) 87 Octane
Requirement (minimum) Rear Travel 10″ (22.9 cm)
ELECTRICAL Spring Adjustment Cam adjustment (rear)
Alternator Max Output 460 Watts @ 3000 RPM WHEELS / BRAKES
Headlights 2 single beam Front Wheel Size / Type 12 x 6 / Steel
50W quartz/halogen Rear Wheel Size / Type 12 x 8 / Steel
Taillights / Brake Lights 10 LED 0.28 Watt / 3.1 Watt Front Tire Model / Size AT489 / 25 x 8 R12
Ignition Timing ECU Controlled Rear Tire Model / Size AT489 / 25 x 11 R12
32° ± 2° @ 5000rpm Front: 10 psi (69 kPa)
Tire Air Pressure Rear: 10 psi (69 kPa)
Spark Plug / Gap NGK MR7F / 0.0276 − 0.0315″
(0.7 – 0.8 mm) Brake System 4 Wheel Hydraulic Disc
Battery / Amp Hr Yuasa Conventional 14 Amp Hr / Brake Fluid DOT 4
12 Volt
Parking Brake Transmission - Park Lock
DC Outlet Standard 12 Volt
GENERAL INFORMATION
MODEL: 2015 RANGER 570

MODEL NUMBER:
R15RMA57AA, AC, AR,
R15RME57AZ
R15RMA57ER, FA
R15RME57ER
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
1074 lbs. / 487 kg
Dry Weight 1101 lbs. / 499 kg (W /
EPS)
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)
GENERAL INFORMATION
2015 RANGER 570 ELECTRICAL
1
only)
EFI: 20 Amp
Bore & Stroke 99 x 73.6 mm EPS (EPS model only): 20 Amp
Accessory: 20 Amp
Compression Ratio 10:1 Drive: 10 Amp
Compression Pressure 80-120 psi (compression release) Lights: 20 Amp
Engine Idle Speed 1200 +/- 100 RPM DRIVETRAIN
Engine Max Speed 7750 RPM Transmission Type Polaris Automatic PVT
Valve Clearance (Intake) 0.005-0.007″ (0.125–0.175 mm) Shift Type In Line Shift - P/ H / L / N / R
Valve Clearance Front Gearcase Lubricant Demand Drive
0.009-0.011″ (0.229–0.275 mm) Requirement 6.7–7.6 oz. (200–225 ml)
(Exhaust)
Oil Requirements PS4 synthetic Transmission Lubricant Full Synthetic AGL
Oil Capacity 2 qts. (1.9 L)
Toe Out 1/8 − 1/4″ (3.20 − 6.35 mm)
FUEL SYSTEM
Type Bosch ME17 EFI
Rear Travel 9″ (22.9 cm)
Requirement (minimum) Spring Adjustment Cam adjustment (rear)
ELECTRICAL WHEELS / BRAKES
Alternator Max Output 460 Watts @ 3000 RPM Front Wheel Size / Type 12 x 6 / Steel
Headlights 2 single beam Rear Wheel Size / Type 12 x 8 / Steel
50W quartz/halogen Front Tire Model / Size AT489 / 25 x 8 R12
Taillights / Brake Lights 10 LED 0.28 Watt / 3.1 Watt Rear Tire Model / Size AT489 / 25 x 11 R12
Ignition Timing ECU Controlled Front: 10 psi (69 kPa)
32° ± 2° @ 5000rpm
Spark Plug / Gap NGK MR7F / 0.0276 − 0.0315″ Brake System 4 Wheel Hydraulic Disc
(0.7 – 0.9 mm) Brake Fluid DOT 4
Battery / Amp Hr Yuasa Conventional 14 Amp Hr / Parking Brake Transmission - Park Lock
12 Volt
GENERAL INFORMATION
MODEL: 2015 RANGER 570 CREW

MODEL NUMBER:
R15RNA57AA, AC, AR
R15RNE57AS
CATEGORY DIMENSION / CAPACITY

Length 140″ / 355.6 cm
Width 60″ / 152.4 cm
Wheel Base 105″ / 266.7 cm
1352 lbs. / 613 kg (W /
EPS)
Vehicle Payload 1250 lbs. / 567 kg
(Includes weight of
riders, cargo and
accessories)
Towing Capacity 1500 lbs. / 680.4 kg
GENERAL INFORMATION
2015 RANGER 570 CREW ELECTRICAL
Instrumentation
Relays
Multifunction Instrument Cluster
EFI / Chassis / Fan / Fuel Pump /
1
ENGINE only)
Domestic Single Cyl., Liquid Circuit Breaker Fan Motor: 20 Amp
Platform Cooled, 4–Stroke, DOHC
Fuses Brake Light: 5 Amp
Engine Displacement 567cc EFI: 20 Amp
Number of Cylinders 1 Fuel Pump: 10 Amp
EPS (EPS model only): 20 Amp
Bore & Stroke 99 x 73.6 mm
Accessory: 20 Amp
Engine Max Speed Transmission Type Polaris Automatic PVT
7750 RPM
Valve Clearance (Intake) 0.005–0.007″ (0.125–0.175 mm) Shift Type In Line Shift - P/ H / L / N / R
0.009–0.011″ (0.229–0.275 mm) Requirement 8.97 oz. (265 ml)
(Exhaust)
Pressurized Dry Sump Transmission Lubricant Full Synthetic AGL
Lubrication
Oil Requirements PS4 synthetic
Toe Out 1/8 − 1/4″ (3.20 − 6.35 mm)
Coolant Capacity 170 Oz (5 L)
FUEL SYSTEM Front Travel 8″ (20.3 cm)
Type Bosch M17 EFI
Rear Travel 9″ (23 cm)
Spring Adjustment Cam Adjustment (rear)
Requirement (minimum) WHEELS / BRAKES
Front Wheel Size / Type 12 x 6 / Steel
ELECTRICAL
Alternator Max Output 460 Watts @ 3000 RPM Rear Wheel Size / Type 12 x 8 / Steel
Headlights 2 single beam Front Tire Model / Size AT489 / 25 x 8 R12

50W quartz/halogen Rear Tire Model / Size AT489 / 25 x 11 R12
Taillights / Brake Lights 10 LED 0.28 Watt / 3.1 Watt Tire Air Pressure Front: 10 psi
Rear: 14 psi
Ignition Timing ECU Controlled
32° ± 2° @ 5000rpm Brake System 4 Wheel Hydraulic Disc
Spark Plug / Gap NGK MR7F / 0.0276 − 0.0315″ Brake Fluid DOT 4
(0.7 – 0.8 mm) Parking Brake Transmission — Park Lock
Battery / Amp Hr Yuasa Conventional 14 Amp Hr /
12 Volt
GENERAL INFORMATION
MODEL: 2016 RANGER ETX

MODEL NUMBER:
R16RMA32A1, A2
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)
GENERAL INFORMATION
2016 RANGER ETX ELECTRICAL
1
only)
EFI: 20 Amp
Bore & Stroke 78 x 68 mm EPS (EPS model only): 20 Amp
Accessory: 20 Amp
Compression Ratio 11.5:1 Drive: 10 Amp
Engine Idle Speed 1250 ±50 RPM Lights: 20 Amp
Engine Max Speed 8500 RPM DRIVETRAIN
Valve Clearance (Intake) 0.005±0.002″ (0.125±0.05 mm) Transmission Type Polaris Automatic PVT
Valve Clearance Shift Type In Line Shift - P/ H / L / N / R
0.0014-0.002″ (0.35±0.05 mm)
(Exhaust) Front Gearcase Lubricant Demand Drive
Oil Requirements PS4 synthetic Requirement 6.7–7.6 oz. (200–225 ml)
Oil Capacity 1.75 qts. (1.61 L) Transmission Lubricant Full Synthetic AGL
FUEL SYSTEM
Toe Out 1/8 − 1/4″ (3.20 − 6.35 mm)
Type Bosch ME17 EFI
Requirement (minimum) Rear Travel 10″ (22.9 cm)
ELECTRICAL Spring Adjustment Cam adjustment (rear)
Alternator Max Output 460 Watts @ 3000 RPM WHEELS / BRAKES
Headlights 2 single beam Front Wheel Size / Type 12 x 6 / Steel
50W quartz/halogen Rear Wheel Size / Type 12 x 8 / Steel
Taillights / Brake Lights 10 LED 0.28 Watt / 3.1 Watt Front Tire Model / Size AT489 / 25 x 8 R12
Ignition Timing ECU Controlled Rear Tire Model / Size AT489 / 25 x 11 R12
32° ± 2° @ 5000rpm Front: 10 psi (69 kPa)
(0.7 – 0.8 mm) Brake System 4 Wheel Hydraulic Disc
Battery / Amp Hr Yuasa Conventional 14 Amp Hr / Brake Fluid DOT 4
12 Volt
Parking Brake Transmission - Park Lock
GENERAL INFORMATION
MODEL: 2016 RANGER 570 4X4

MODEL NUMBER:
R16RMA57A1, A4, A9, F1, N1, F1E, F1T
R16RME57AS, A9, FH, FHE, FHT
R16RMS57F1
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
1074 lbs. / 487 kg
Dry Weight 1101 lbs. / 499 kg (W /
EPS)
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)
GENERAL INFORMATION
2016 RANGER 570 4X4 ELECTRICAL
1
only)
EFI: 20 Amp
Accessory: 20 Amp
0.009-0.011″ (0.229–0.275 mm) Requirement 6.7–7.6 oz. (200–225 ml)
(Exhaust)
Toe Out 1/8 − 1/4″ (3.20 − 6.35 mm)
FUEL SYSTEM
Type Bosch ME17 EFI
32° ± 2° @ 5000rpm
12 Volt
GENERAL INFORMATION
MODEL: 2016 RANGER 570 2X4 (INTL.)

MODEL NUMBER:
R16RM257N1
DIMENSION /
CATEGORY
CAPACITY
Length 110″ / 279.4 cm
Width 58″ / 147.3 cm
1000 lbs. / 454 kg
(Includes weight of
Vehicle Payload
riders, cargo and
accessories)
GENERAL INFORMATION
2016 RANGER 2X4 (INTL.) ELECTRICAL
1
only)
EFI: 20 Amp
Accessory: 20 Amp
Valve Clearance Front Gearcase Lubricant
0.009-0.011″ (0.229–0.275 mm) Requirement N/A
(Exhaust)
Toe Out 1/8 − 1/4″ (3.20 − 6.35 mm)
FUEL SYSTEM
Type Bosch ME17 EFI
32° ± 2° @ 5000rpm
12 Volt
GENERAL INFORMATION
MODEL: 2016 RANGER 570 CREW

MODEL NUMBER:
R16RNA57A1, A4, A9
R16RNE57AH
CATEGORY DIMENSION / CAPACITY

Length 140″ / 355.6 cm
Width 60″ / 152.4 cm
Wheel Base 105″ / 266.7 cm
1352 lbs. / 613 kg (W /
EPS)
Vehicle Payload 1250 lbs. / 567 kg
(Includes weight of
riders, cargo and
accessories)
Towing Capacity 1500 lbs. / 680.4 kg
2016 RANGER 570 CREW ENGINE

Number of Cylinders 1
Model Specifications Bore & Stroke 99 x 73.6 mm
ENGINE Compression Ratio 10:1
Domestic Single Cyl., Liquid Compression Pressure 80-120 psi (compression release)
Platform Cooled, 4–Stroke, DOHC Engine Idle Speed 1200 +/- 100 RPM
Engine Displacement 567cc
GENERAL INFORMATION
ENGINE STEERING / SUSPENSION

Engine Max Speed 7750 RPM Rear Travel 9″ (23 cm)
1
Valve Clearance (Intake) 0.005–0.007″ (0.125–0.175 mm) Spring Adjustment Cam Adjustment (rear)
Valve Clearance WHEELS / BRAKES
0.009–0.011″ (0.229–0.275 mm)
(Exhaust) Front Wheel Size / Type 12 x 6 / Steel
Lubrication Pressurized Dry Sump Rear Wheel Size / Type 12 x 8 / Steel
Oil Requirements PS4 synthetic Front Tire Model / Size AT489 / 25 x 8 R12
Oil Capacity 2 qts. (1.9 L) Rear Tire Model / Size AT489 / 25 x 11 R12
Coolant Capacity 170 Oz (5 L) Tire Air Pressure Front: 10 psi
Rear: 14 psi
FUEL SYSTEM
Type Bosch M17 EFI Brake System 4 Wheel Hydraulic Disc
Fuel Delivery Electronic Fuel Pump (in-tank) Brake Fluid DOT 4
Parking Brake Transmission — Park Lock
Requirement (minimum)
ELECTRICAL
Alternator Max Output 460 Watts @ 3000 RPM
Headlights 2 single beam
50W quartz/halogen
Taillights / Brake Lights 10 LED 0.28 Watt / 3.1 Watt
Ignition Timing ECU Controlled
32° ± 2° @ 5000rpm
(0.7 – 0.8 mm)
Battery / Amp Hr Yuasa Conventional 14 Amp Hr /
12 Volt
Instrumentation Multifunction Instrument Cluster
only)
Circuit Breaker Fan Motor: 20 Amp
Fuses Brake Light: 5 Amp
EFI: 20 Amp
Fuel Pump: 10 Amp
EPS (EPS model only): 20 Amp
Accessory: 20 Amp
Drive: 10 Amp
Lights: 20 Amp
DRIVETRAIN
Transmission Type Polaris Automatic PVT
Shift Type In Line Shift - P/ H / L / N / R
Front Gearcase Lubricant Demand Drive
Transmission Lubricant Full Synthetic AGL
Toe Out 1/8 − 1/4″ (3.20 − 6.35 mm)
GENERAL INFORMATION
MISC. SPECIFICATIONS AND CHARTS

PUBLICATION NUMBERS
OWNER’S PARTS MANUAL
MODEL MODEL NO.
MANUAL PN PN
2015 RANGER ETX R15RMA32AA, AJ
9925357
2015 RANGER ETX INTL R15RMA32FA
2015 RANGER 570 R15RMA57AA, AC, AR
2015 RANGER 570 EPS R15RME57AZ
9925356 9925358
2015 RANGER 570 INTL R15RMA57ER, FA
2015 RANGER 570 HD INTL R15RME57ER
2015 RANGER 570 CREW R15RNA57AA, AC, AR
9925785
2015 RANGER 570 CREW EPS R15RNE57AS
2016 RANGER ETX R16RMA32A1, A2 9926356
2016 RANGER 570 R16RMA57A1, A4, A9
2016 RANGER 570 EPS R16RME57AS, A9
9926357
R16RMA57L1, 9926455
2016 RANGER 570 HD INTL
R16RMH57AR
2016 RANGER 570 CREW R16RNA57A1, A4, A9
9926476
2016 RANGER 570 CREW EPS R16RNE57AH
2016 RANGER 570 2X4 (Intl.) R16RM257N1
2016 RANGER 570 (Intl.) R16RMA57N1,

R16RMA57F1 9926462
9926473
2016 RANGER 570 EPS (Intl.) R16RME57FH,
R16RME57NH
2016 RANGER 570 EPS (Intl.) R16RMS57F1 9926462-DE
NOTE
When ordering service parts be sure to use the correct parts manual.
Polaris factory publications can be found at www.polaris.com or purchased from www.purepolaris.com.
GENERAL INFORMATION
SPECIAL TOOLS
Special tools may be required while servicing this vehicle. Some of the tools listed or depicted are mandatory, while
other tools may be substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools
1
when servicing any Polaris product. Dealers may order special tools through the Polaris official tool supplier.
Bosch Automotive Service Solutions 1-800-345-2233 or https://polaris.service-solutions.com
GENERAL INFORMATION
REPLACEMENT KEYS
Replacement keys can be made from the original key. To
identify which series the key is, take the first two digits on
the original key and refer to the chart to the right for the
proper part number.
SERIES# PART NUMBER

20 4010278
21 4010278
22 4010321
23 4010321
27 4010321
28 4010321
31 4110141
32 4110148
67 4010278
68 4010278
GENERAL INFORMATION
MASTER SPECIAL TOOLS TABLE

ENGINE / COOLING SYSTEM
1
GENERAL
Bench Mount Engine Stand Adapter Engine Stand (2” Bore) Engine Stand Adapter
PW-47053 PU - 50624-A (Mounts To The Engine)
PU-50824-A
Engine Stand Sleeve Adapter Engine Stand Sleeve Adapter Flywheel Puller
(Use With 2” Bore Stand) (Use With 2.375” Bore Stand) PA-49316
PU-50625 PW-47054
Stator Cover Removal Handles Valve Spring Compressor Water Pump Seal Installation Tool
PA-49317 PV-1253 PU-50869
GENERAL INFORMATION

325
Crankshaft-Balance Shaft Holder Camshaft Alignment Tool Camshaft Sprocket Holder
PA-51424 PA-51423 PA-51430
Flywheel Holding Tool Valve spring Compressor Adapter Oil Pressure Gauge
PU-51220 PU-51038 (0-10 PSI / .69 - 69 KPa)
Commercially Available
Water Pump Seal Puller

2872105-A
GENERAL INFORMATION

570 1
Cylinder Holding & Crankshaft Removal / Installation Oil Filter Wrench
Camshaft Timing Plate Tool Kit PU-50105
PU-50563 PU-50784
Oil Pressure Gauge Oil Pressure Gauge Adapter Valve Spring Compressor Adapter
PV-43531 PU-50569 PV-43513-A
GENERAL INFORMATION
FUEL SYSTEM
Digital Wrench Kit Digital Wrench Smart *Serial Number Registration Card
PU-47063-C Link Module Kit PU-48731-A
PU-47471
(Includes: PU-47470, PU-47469,
PU-47468)
*Digital Wrench® PC Interface Cable *Digital Wrench® Vehicle *Digital Wrench® SmartLink Module
PU-47470 Interface Cable PU-47468
PU-47469
Digital Wrench® Wireless Fuel Pressure Gauge Kit Fuel Pressure Gauge Adapter
Vehicle Link PU-43506-A PV-48656
PU-51435
GENERAL INFORMATION
FUEL SYSTEM
Fuel Pressure Gauge Adapter Fluke 77 Digital Multi-Meter Throttle Position Sensor Tester Kit 1
PS-48762 (Fluke 77: PV-43568) 2201519-A
(Includes: 547927, PU-47466)
Laptop or Desktop Computer USB/

Serial Adaptor: Saelig RS-232
Commercially Available (refer to
diagnostic software user manual or
HELP section for minimum
requirements)
GENERAL INFORMATION
PTV SYSTEM
Clutch Bushing Replacement Drive Clutch Puller - Short Drive Clutch Holding Tool
Tool Kit PA-48595 9314177-A
2871226
Drive Clutch Spider Removal Piston Pin Puller Roller Pin Tool
and Install Tool 2870386 2870910-A
2870341
Universal Clutch Compressor Tool Standard Clutch Alignment Tool Clutch Center Distance Tool
PU-50518-A 2870654 PU-50658-A
GENERAL INFORMATION
TRANSMISSION
Bearing Seal Driver (50 mm) Backlash Setting Tool Rear Driveshaft Seal Guide 1
2871282 2871695 (Part of 2871702 Kit) 2871699 (Part of 2871702 Kit)
Rear Output Seal Driver Snorkel Tool Transmission Nut Socket

2871698 (Part of 2871702 Kit) PA-50231 PU-50566
FINAL DRIVE
1 3/4” Straight Wrench ADC Gearcase Piston CV Boot Clamp Pliers
2870772 Installation Tool 8700226 or PU-48951
PA-48542
Roller Pin Removal Tool

2872608
GENERAL INFORMATION
Ball Joint Removal / Installation Tool Strut Compression Tools Shock Absorber Spring
2870871 2871573, 2871574 Compression Tool
2870623
BRAKES
Mity Vac® Pressure Test Tool
2870975
BODY / FRAME
Multi-Function Pliers
2876389
GENERAL INFORMATION
ELECTRICAL
Battery Conductance Analyzer Battery Hydrometer Fluke® 77 Digital Multimeter 1
PU-50296 PU-50338 PV-43568
Hall Sensor Probe Harness Static Timing Light Harness Timing Light
2460761 2871745 2870630
GENERAL INFORMATION
MASTER TORQUE TABLE

ITEM TORQUE ITEM TORQUE
Ball Joint Nut 30 ft-lbs (41 Nm) Torque The Outer M6
Head Bolts 89 ± 9 in-lbs
Ball Joint Retaining Plate 8 ft-lbs (11 Nm) (10 ± 1 Nm)
Screws
Bearing Carrier Fasteners 40 ft-lbs (54 Nm) Apply light coat of engine
oil to bolt threads and
Body Screws (T-40) 8 ft-lbs (11 Nm) under bolt head
Brake Disc Mounting Bolts Torque in Sequence for all
18 ft-lbs (25 Nm) steps
(front)
Step 1: 18 ft-lbs (25 Nm)
Brake Disc Mounting Bolts
27 ft-lbs (36 Nm) Step 2: 30 ft-lbs (40 Nm)
(rear)
Step 3: Loosen all
Brake Bleed Screws 47 in-lbs (5 Nm) Cylinder Head Bolts - Silver fasteners until they are
Brake Caliper Mounting unseated
46 ft-lbs (62 Nm)
Bolts Step 4: 15 ft-lbs (20 Nm)
Brake Line Banjo Bolts 15 ft-lbs (20 Nm) Step 5: 26 ft-lbs (35 Nm)
Step 6: Additional 180°
Brake Line Flare Fittings 14 ft-lbs (19 Nm)
Brake Switch 15 ft-lbs (20 Nm)
Torque The Outer M6
Cam Chain Tensioner 30 ft-lbs (41 Nm) Head Bolts 89 ± 9 in-lbs
(10 ± 1 Nm)
Cam Chain Guide 9 ft-lbs (12 Nm)
Fasteners Differential Cover Screws 22 ft-lbs (30 Nm)
Camshaft Carrier Bolts 8 ft-lbs (11 Nm) Drive Clutch Retaining Bolt 45 ft-lbs (61 Nm)
Camshaft Sprocket Bolts 33 ft-lbs (45 Nm) Driven Clutch Retaining 38 ft-lb (52 Nm)
Bolt
Chassis Ground Fastener 54 in-lbs (6 Nm)
Drive Clutch Cover Plate 8 ft-lbs (10 Nm)
Control Arm Fasteners Screw
40 ft-lbs (54 Nm)
(front and rear)
Drive Clutch Spider 290 ft-lbs (393 Nm)
Coolant Bleed Screw 72 in-lbs (8 Nm)
Drive Clutch Spring
12 ft-lbs (16 Nm)
Coolant Temperature 17 ft-lbs (23 Nm) Retaining Ring Bolts
Sensor
Driven Clutch Retaining 38 ft-lbs (51 Nm)
CPS Retaining Bolt 9 ft-lbs (12 Nm) Bolt
Crankcase Bolts 22 ft-lbs (30 Nm) ETC Fasteners 7 ft-lbs (10 Nm)
Crankshaft Bearing ECU Mounting Screws 10 in-lbs (1 Nm)
8 ft-lbs (11 Nm)
Retainer (PTO)
Engine Oil Plug 14 ft-lbs (19 Nm)
Cylinder Head Torque Engine Oil Gallery Plug 11 ft-lbs (15 Nm)
Procedure:
Step 1:Torque the (4) M8 Engine Mount (front) 40 ft-lbs (54 Nm)
Nuts in Sequence to 15 ft- In Sequence:
lbs (20 Nm) Engine/Transmission
Cylinder Head Bolts - 325 95 ft-lbs (195 Nm)
Mounting Bolts (325)
Engine Step 2:Torque the (4) M8 *see procedure for sequence
Nuts in Sequence 180° (1/
2 turn) In Sequence:
Engine/Transmission
55 ft-lb (75 Nm)
Step 3:Torque the Outer Mounting Bolts (570)
*see procedure for sequence
M6 Head Bolts to 9 ft-lbs
(12 ± 1 Nm) Exhaust Head Pipe Bolts 18 ft-lbs (25 Nm)
Torque in sequence for all Flywheel Nut 133 ft-lbs (180 Nm)
steps Frame Bolts (front to rear) 40 ft-lbs (54 Nm)
Cylinder Head Bolts - Black Step 1: 21 ft-lbs (28 Nm) CREW
Step 2: 26 ft-lb (35 Nm) Front Bumper / Fender 5 ft-lbs (7 Nm)
Step 3: Additional 135° Screws
GENERAL INFORMATION
ITEM TORQUE ITEM TORQUE

Front Gearcase Cover
Plate Screws
11 ft-lbs (15 Nm) Stator Mounting Bolts 9 ft-lbs (12 Nm) 1
Stator Wire Retainer 6 ft-lbs (9 Nm)
Front Gearcase Drain/Fill
10 ft-lbs (14 Nm) Steering Rack Mounting
Plugs 16 ft-lbs (22 Nm)
Bolts
Front Gearcase Mounting 33 ft-lbs (56 Nm)
Bolts Steering Shaft to EPS Unit 20 ft-lbs (27 Nm)
Fuel Pump PFA Nut 70 ft-lbs (90 Nm) Steering Shaft to Steering 46–51 ft-lbs (62-69 Nm)
Rack
Fuel Rail Mounting Screws 7 ft-lbs (10 Nm)
Steering Wheel Nut 65 ft-lbs (88 Nm)
Fuel Tank Mounting Screw 17 ft-lbs (23 Nm)
Strut Casting Pinch Bolt 26 ft-lbs (35 Nm)
Hub Castle Nut (front) 90 ft-lbs (122 Nm)
Strut Mounting Nut (top) 15 ft-lbs (21 Nm)
Hub Castle Nut (rear) 110 ft-lbs (150 Nm)
Thermostat Cover Bolts 8 ft-lbs (11 Nm)
IAC Mount Screw 18 in-lbs (2 Nm)
Tie Rod End to Knuckle 40 ft-lbs (54 Nm)
Master Cylinder Mount 17 ft-lbs (23 Nm)
Bolts Tie Rod Jamb Nuts 14 ft-lbs (19 Nm)
Oil Pump Cover Bolt 8 ft-lbs (11 Nm) TMAP Retaining Bolt 24 in-lbs (3 Nm)
Power Steering Bracket to TPS Mounting Screws 18 in-lbs (2 Nm)

15 ft-lbs (20 Nm)
Frame Nuts
Transmission Bell Crank 15 ft-lbs (20 Nm)
Power Steering Unit to 30 ft-lbs (41 Nm) Nut
Mount Bracket
Transmission Case Screws 18 ft-lbs (24 Nm)
Prop Shaft Support Bearing 36 ft-lbs (49 Nm)
Fasteners Transmission Drain / Fill
14 ft-lbs (19 Nm)
Plugs
Prop Shaft Support Bearing 35 in-lbs (4 Nm)
Set Screws Transmission Isolator Bolt
40 ft-lbs (54 Nm)
(rear)
PVT Inner Cover Screws
50 in-lbs (5 Nm)
(Phillips) Transmission Rear Mount 17 ft-lbs (23 Nm)
Bracket Fasteners
PVT Inner Cover Screws
12 ft-lbs (16 Nm) Transmission Joint Bracket
(Hex) ft-lbs ( Nm)
Bolts
PVT Outer Cover Screws 50 in-lbs (5 Nm)
Transmission Park Flange 8 ft-lbs (11 Nm)
Seat Belt Mounting 40 ft-lbs (54 Nm) Screws
Fasteners
Transmission Sector Gear 11 ft-lbs (15 Nm)
Shift Cable Bracket Bolts 37 ft-lbs (50 Nm) Cover
Shock Mounting Fasteners Transmission Shift Fork 10 ft-lbs (14 Nm)
40 ft-lbs (54 Nm) Screws
(rear)
8 ft-lbs (11 Nm) Transmission Snorkel
Skid Plate Fasteners 8 ft-lbs (11 Nm)
Bearing Retaining Plate
9 ft-lbs (12 Nm) Screws
Spark Plug
w/o anti-seize Transmission Snorkel Tube
8 ft-lbs (11 Nm)
Speed Sensor Screw 10 ft-lbs (14 Nm) Locking Screw
Stabilizer Bar Linkage TRS Retaining Nuts 7 ft-lbs (10 Nm)
17 ft-lbs (23 Nm)
(rear)
TPS Mounting Screws 18 in-lbs (2 Nm)
Stabilizer Bar Mounting
17 ft-lbs (23 Nm) Valve Cover Bolts 9 ft-lbs (12 Nm)
Bracket Bolts (rear)
Starter Mounting Bolts 3 ft-lbs (4 Nm) Water Pump Impeller Finger Tight *LH threads
Starter Power Wire Nut 54 in-lbs (6 Nm) 9 ft-lbs (12 Nm)

Water Pump Cover Bolts (Apply Loctite® 204™ to bolt
Starter One-Way Clutch 9 ft-lbs (12 Nm) threads)
Bolts
Stator Cover Screws 9 ft-lbs (12 Nm)
GENERAL INFORMATION
ITEM TORQUE
Wheel Lug Nuts (Steel
36 ft-lbs (49 Nm)
Wheels)
Wheel Lug Nuts (Aluminum
30 ft-lbs + 90º (41 Nm + 90º)
Wheels)
GENERAL INFORMATION
CLUTCHING CHART
RANGER ETX
1
SHIFT DRIVE
ALTITUDE
WEIGHT SPRING
Red /
0-1800 10 RHF
Orange
(0-6000) (5632282)
Meters (7044321)
(Feet) Red /
1800-3700 10-40
Orange
(6000 - 12000) (5633331)
(7044321)
RANGER 570
SHIFT DRIVE
ALTITUDE
WEIGHT SPRING
0-1800 25–52G Black
Meters (0-6000) (5632409) (7043594)
(Feet) 1800-3700 25-48 Black
(6000 - 12000) (5633217) (7043594)
RANGER CREW 570
SHIFT DRIVE
ALTITUDE
WEIGHT SPRING
0-1800 25-52G Black
Meters (0-6000) (5632409) (7043594)
(Feet) 1800-3700 25-48 Black
(6000 - 12000) (5633217) (7043594)
GENERAL INFORMATION
CONVERSION TABLE
UNIT OF MEASURE MULTIPLIED BY CONVERTS TO
ft-lbs x 12 = in-lbs
in-lbs x 0.0833 = ft-lbs
ft-lbs x 1.356 = Nm
in-lbs x 0.0115 = kg-m
Nm x 0.7376 = ft-lbs
kg-m x 7.233 = ft-lbs
kg-m x 86.796 = in-lbs
kg-m x 10 = Nm
inch x 25.4 = mm
mm x 0.03937 = inch
inch x 2.54 = cm
mile (mi) x 1.6 = km
km x 0.6214 = mile
ounces (oz) x 28.35 = grams (g)
fluid ounces (fl oz) x 29.57 = cubic centimeters (cc)
cubic centimeters (cc) x .03381 = fluid ounces
grams (g) x 0.035 = ounces
pounds (lb) x 0.454 = kg

kilogram (kg) x 2.2046 = lbs
cubic inches (cu in) x 16.387 = cc
cubic centimeters (cc) x 0.061 = cubic inches

US quarts x 0.946 = liters (L)
liters (L) x 1.057 = US quarts
US gallons x 3.785 = liters (L)
liters (L) x 0.264 = US gallons
PSI x 6.895 = kilopascals (kPa)
kilopascals (kPa) x 0.145 PSI
π (3.14) x Radius² x Height = = cylinder volume
°C to °F: 9/5 (°C + 32) = °F
°F to °C: 5/9 (°F − 32) = °C
GENERAL INFORMATION
STANDARD BOLT TORQUE SPECIFICATION

GRADE 2 GRADE 5 GRADE 8
1
BOLT SIZE FT-LB (NM) FT-LB (NM) FT-LB (NM)
1/4-20 5 (7) 8 (11) 12 (16)
1/4-28 6 (8) 10 (14) 14 (19)
5/16-18 11 (15) 17 (23) 25 (35)
5/16-24 12 (16) 19 (26) 29 (40)
3/8-16 20 (27) 30 (40) 45 (62)
3/8-24 23 (32) 35 (48) 50 (69)
7/16-14 30 (40) 50 (69) 70 (97)
7/16-20 35 (48) 55 (76) 80 (110)
1/2-13 50 (69) 75 (104) 110 (152)
1/2-20 55 (76) 90 (124) 120 (166)
METRIC BOLT TORQUE SPECIFICATION

GRADE
BOLT 4.6 4.8 8.8 / 8.9 10.9 12.9
SIZE
FT-LB (NM) DRY THREADS
M3 0.3 (0.5) 0.5 (0.7) 1 (1.3) 1.5 (2) 1.5 (2)
M4 0.8 (1.1) 1 (1.5) 2 (3) 3 (4.5) 4 (5)
M5 1.5 (2.5) 2 (3) 4.5 (6) 6.5 (9) 7.5 (10)
M6 3 (4) 4 (5.5) 7.5 (10) 11 (15) 13 (18)
M8 7 (9.5) 10 (13) 18 (25) 26 (35) 33 (45)
M10 14 (19) 18 (25) 37 (50) 55 (75) 63 (85)
M12 26 (35) 33 (45) 63 (85) 97 (130) 111 (150)
M14 37 (50) 55 (75) 103 (140) 151 (205) 177 (240)
M16 59 (80) 85 (115) 159 (215) 232 (315) 273 (370)
M18 81 (110) 118 (160) 225 (305) 321 (435) 376 (510)
GENERAL INFORMATION
SAE TAP / DRILL SIZES

THREAD SIZE DRILL SIZE THREAD SIZE DRILL SIZE
#0–80 3/64 1/2–13 27/64
#1–64 53 1/2–20 29/64
#1–72 53 9/16–12 31/64
#2–56 51 9/16–18 33/64
#2–64 50 5/8–11 17/32
#3–48 5/64 5/8–18 37/64
#3–56 45 3/4–10 21/32
#4–40 43 3/4–16 11/16
#4–48 42 7/8–9 49/64
#5–40 38 7/8–14 13/16
#5–44 37 1–8 7/8
#6–32 36 1–12 59/64
#6–40 33 1 1/8–7 63/64
#8–32 29 1 1/8–12 1 3/64
#8–36 29 1 1/4–7 1 7/64
#10–24 24 1 1/4–12 1 11/64
#10–32 21 1 1/2–6 1 11/32
#12–24 17 1 1/2–12 1 27/64
#12–28 4.6 mm 1 3/4–5 1 9/16
1/4–20 7 1 3/4–12 1 43/64
1/4–28 3 2–4 1/2 1 25/32
5/16–18 F 2–12 1 59/64
5/16–24 I 2 1/4–4 1/2 2 1/32
3/8–16 O 2 1/2–4 2 1/4
3/8–24 Q 2 3/4–4 2 1/2
7/16–14 U 3–4 2 3/4
7/16–20 25/64
GENERAL INFORMATION
METRIC TAP / DRILL SIZES

TAP SIZE DRILL SIZE DECIMAL EQUIVALENT NEAREST FRACTION 1
3 x .50 #39 0.0995 3/32
3 x .60 3/32 0.0937 3/32
4 x .70 #30 0.1285 1/8
4 x .75 1/8 0.125 1/8
5 x .80 #19 0.166 11/64
5 x .90 #20 0.161 5/32
6 x 1.00 #9 0.196 13/64
7 x 1.00 16/64 0.234 15/64
8 x 1.00 J 0.277 9/32
8 x 1.25 17/64 0.265 17/64
9 x 1.00 5/16 0.3125 5/16
9 x 1.25 5/16 0.3125 5/16
10 x 1.25 11/32 0.3437 11/32
10 x 1.50 R 0.339 11/32
11 x 1.50 3/8 0.375 3/8
12 x 1.50 13/32 0.406 13/32
12 x 1.75 13/32 0.406 13/32
GENERAL INFORMATION
DECIMAL EQUIVALENTS
FRACTION DECIMAL MM TO INCHES
1/64 0.0156″
1/32 0.0312″ 1 mm = 0.0394″
3/64 0.0469″
1/16 0.0625″
5/64 0.0781″ 2 mm = 0.0787″
3/32 0.0938″
7/64 0.1094″ 3 mm = 0.1181″
1/8 0.1250″
9/64 0.1406″
5/32 0.1563″ 4 mm = 0.1575″
11/64 0.1719″
3/16 0.1875″ 5 mm = 0.1969″
13/64 0.2031″
7/32 0.2188″
15/64 0.2344″ 6 mm = 0.2362″
1/4 0.25″
17/64 0.2656″ 7 mm = 0.2756″
9/32 0.2813″
19/64 0.2969″
5/16 0.3125″ 8 mm = 0.3150″
21/64 0.3281″
11/32 0.3438″ 9 mm = 0.3543″
23/64 0.3594″
3/8 0.375″
25/64 0.3906″ 10 mm = 0.3937″
13/32 0.4063″
27/64 0.4219″ 11 mm = 0.4331″
7/16 0.4375″
29/64 0.4531″
15/32 0.4688″ 12 mm = 0.4724″
31/64 0.4844″
1/2 0.500″ 13 mm = 0.5118″
33/64 0.5156″
17/32 0.5313″
35/64 0.5469″ 14 mm = 0.5512″
9/16 0.5625″
37/64 0.5781″ 15 mm = 0.5906″
19/32 0.5938″
39/64 0.6094″
5/8 0.625″ 16 mm = 0.6299″
GENERAL INFORMATION
FRACTION DECIMAL MM TO INCHES

41/64 0.6406″ 1
21/32 0.6563″ 17 mm = 0.6693″
43/64 0.6719″
11/16 0.6875″
45/64 0.7031″ 18 mm = 0.7087″
23/32 0.7188″
47/64 0.7344″ 19 mm = 0.7480″
3/4 0.750″
49/64 0.7656″
25/32 0.7813″ 20 mm = 0.7874″
51/64 0.7969″
13/16 0.8125″ 21 mm = 0.8268″
53/64 0.8281″
27/32 0.8438″
55/64 0.8594″ 22 mm = 0.8661″
7/8 0.875″
57/64 0.8906″ 23 mm = 0.9055″
29/32 0.9063″
59/64 0.9219″
15/16 0.9375″ 24 mm = 0.9449″
61/64 0.9531″
31/32 0.9688″ 25 mm = 0.9843″
63/64 0.9844″
1 1.000″
GENERAL INFORMATION
NOTES
MAINTENANCE
CHAPTER 2
MAINTENANCE
2
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4
BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
VEHICLE BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
ENGINE AND DRIVETRAIN BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
BRAKE SYSTEM BREAK-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
PVT BREAK-IN (CLUTCHES / BELT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
INSPECTION / MAINTENANCE INTERVALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
PRE-RIDE / DAILY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
COLD WEATHER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
PERIODIC MAINTENANCE CHART KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
PERIODIC MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.7
GREASE LUBRICATION POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.10
COMPONENT QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
COMPONENT QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.12
SERVICE PRODUCTS AND LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.14
GENERAL MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
FRAME, NUTS, BOLTS, AND FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
SHIFT CABLE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
SHIFT CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.15
STORAGE TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.16
FUEL SYSTEM AND AIR INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
FUEL LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
FUEL PUMP / FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
VENT LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
THROTTLE PEDAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
AIR FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.17
ENGINE AIR INTAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
PVT AIR INTAKE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.18
ENGINE COMMON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
COMPRESSION AND LEAKDOWN TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.19
ENGINE - 325. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
ENGINE OIL LEVEL CHECK - 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.20
ENGINE OIL AND FILTER CHANGE - 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.21
VALVE CLEARANCE INSPECTION - 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.22
ENGINE BREATHER - 325. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.24
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
ENGINE OIL LEVEL - 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
OIL AND FILTER CHANGE - 570. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.25
MAINTENANCE
VALVE CLEARANCE - DOHC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.26

BREATHER HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
BREATHER VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.27
TRANSMISSION AND GEARCASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
TRANSMISSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.28
FRONT GEARCASE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.29
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
COOLING SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
COOLANT LEVEL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.30
50/50 EXTENDED-LIFE ENGINE ANTIFREEZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.32
COOLANT STRENGTH / TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
COOLING SYSTEM HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.33
RADIATOR INSPECTION / CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.34
FINAL DRIVE / WHEEL AND TIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
WHEEL AND HUB TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
CV SHAFT BOOT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
WHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.36
WHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
TIRE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.37
ELECTRICAL AND IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
BATTERY FLUID LEVEL (CONVENTIONAL BATTERY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
BATTERY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.38
BATTERY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
BATTERY STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
SPARK PLUG SERVICE - 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.39
MAIN FRAME/ENGINE GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.40
STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.41
STEERING INSPECTION NOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.41
TIE ROD END / STEERING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.41
WHEEL TOE ALIGNMENT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.42
TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.42
CAMBER AND CASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.43
SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.44
SUSPENSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.44
SPRING PRE-LOAD ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.44
STABILIZER BAR PIVOT LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.44
SUSPENSION PIVOT POINT LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.44
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.45
BRAKE FLUID INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.45
BRAKE HOSE AND FITTING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.45
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.45
BRAKE DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.46
PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.46
MAINTENANCE
PARKING BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.47
MAINTENANCE
GENERAL INFORMATION
SPECIAL TOOLS
MAINTENANCE
BREAK-IN PERIOD
VEHICLE BREAK-IN PERIOD NOTE
The break-in period for your new POLARIS vehicle is the Excessive heat build-up during the first three hours of
first 25 hours of operation, or the time it takes to use the operation will damage close-fitted engine parts and
first two tanks full of gasoline. No single action on your drive components. Do not operate at full throttle or high
part is as important as a proper breakin period. Careful speeds during the first three hours of use. 2
treatment of a new engine and drive components will
result in more efficient performance and longer life for Use of any oils other than those recommended by
these components. Perform the following procedures POLARIS may cause serious engine damage. We
carefully. recommend the use of POLARIS PS-4 Full Synthetic
5W-50 4-Cycle Oil for your 4-cycle engine.
ENGINE AND DRIVETRAIN BREAK-IN

1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever handling gasoline.
2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the safe operating range.
3. Complete the New Operator Driving Procedures outlined in the vehicle Owner’s Manual.
4. Avoid aggressive use of the brakes.
5. Vary throttle positions. Do not operate at sustained idle.
6. Pull only light loads.
7. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist.
8. During the break-in period, change both the oil and the filter at 25 hours or one month.
9. Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours
thereafter.
BRAKE SYSTEM BREAK-IN

Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is
new could damage brake pads and rotors.
PVT BREAK-IN (CLUTCHES / BELT)

A proper break-in of the clutches and drive belt will
ensure a longer life and better performance. Break in the
clutches and belt by operating at slower speeds during
the break-in period as recommended. Pull only light
loads. Avoid aggressive acceleration and high speed
operation during the break-in period.
If a belt fails, always clean away all debris when
replacing the belt.
MAINTENANCE
INSPECTION / MAINTENANCE INTERVALS

PRE-RIDE / DAILY INSPECTION
Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
• Tires - check condition and pressures
• Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank
• All brakes - check operation and adjustment (includes auxiliary brake)
• Throttle - check for free operation and closing
• Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
• Ignition switch - check for proper function
• Wheels - check for tightness of wheel nuts and axle nuts; check to be sure axle nuts are secured by cotter pins
• Air cleaner element - check for dirt; clean or replace
• Steering - check for free operation noting any unusual looseness in any area
• Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
• Engine coolant - check for proper level at the recovery bottle
• Check all rear suspension components for wear or damage
COLD WEATHER OPERATION

If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of
contaminates such as water or excess fuel in the bottom of the crankcase. Water in the bottom of the crankcase can
lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases.
MAINTENANCE
PERIODIC MAINTENANCE CHART KEY

SYMBOL DESCRIPTION
► Perform these operations more often for vehicles subjected to severe use.
E Emission-related Control System Service (California)
Failure to conduct this maintenance will not void the emissions warranty but may affect
emissions 2
■ Have an authorized POLARIS dealer perform these services.
SEVERE USE ITEM: Severe Use is defined as frequent vehicle immersion in mud, water or sand, racing or race-style
high rpm use, prolonged low speed - heavy load operation or extended idle. More preventative maintenance is
required under these conditions. Fluid changes, cable and chassis lubrication are required more frequently. For engine
oil, short trip cold weather riding also constitutes severe use. Pay special attention to oil level. A rising oil level in cold
weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately and monitor level. If
oil level begins to rise, discontinue use and determine cause.
NOTE
Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
WARNING
Improperly performing the procedures marked with a ■ could result in component failure and lead to serious injury or
death. Have an authorized Polaris dealer perform these services.
PERIODIC MAINTENANCE CHART

MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
HOUR- CALEN-
ITEM S DAR MILES (KM) REMARKS
Steering - Pre-Ride -
Front-suspension - Pre-Ride -
Rear-suspension - Pre-Ride -
Tires - Pre-Ride -
Brake fluid level - Pre-Ride -
Make adjustments as needed.
Brake pedal travel - Pre-Ride -
Brake systems - Pre-Ride -
Wheels /fasteners - Pre-Ride -
Frame fasteners - Pre-Ride -
Engine Oil Level - Pre-Ride -
▶ Daily
Air filter, pre-filter - - Inspect; clean often; replace as needed
E
Coolant - Daily - Check level
Power Steering unit (if
▶ equipped) - Daily - Inspect daily; clean often
Head lamp / tail lamp / Check operation; apply dielectric grease to

- Daily -
worklight electrical connections if replacing lamps
▶ Weekly
Air filter - - Inspect; replace as needed
E
▶ Brake pad wear Monthly - Inspect periodically
10 H
D
Battery 20 H Monthly - Check terminals; clean; test
MAINTENANCE
HOUR- CALEN-
▶ Engine breather Monthly
25 H - Inspect; replace as needed
E filter (if equipped)
Inspect; Cycle the Key to pressurize the fuel
Fuel System 25 H Monthly - pump; check lines and fittings for leaks and
abrasion.
Front Gearcase oil (if
▶ equipped) 25 H Monthly - Perform a break-in oil level check
Middle Gearcase oil (if
▶ equipped) 25 H Monthly - Perform a break-in oil level check
Rear gearcase oil (if
▶ 25 H Monthly - Perform a break-in oil level check
equipped)
▶ Transmission fluid 25 H Monthly - Perform a break-in oil level check
Engine oil change
▶ (break-in) 25 H Monthly - Perform a break-in oil change at one month
▶ General lubrication 50 H 3M - Lubricate all grease fittings, pivots, cables, etc.

Shift Linkage 50 H 6M - Inspect, lubricate, adjust
D Steering 50 H 6M - Lubricate
▶ Front Suspension 50 H 6M - Lubricate
▶ Rear Suspension 50 H 6M - Lubricate
D Throttle Cable/ 500 (800) Inspect; adjust; lubricate; replace if necessary
50 H 6M
E Release Switch
Throttle body air intake
E ducts/ 50 H 6M 500 (800) Inspect ducts for proper sealing/air leaks
flange
Drive belt 50 H 6M 500 (800)
Inspect coolant strength seasonally; pressure
▶ Cooling system 50 H 6M -
test system yearly
Engine oil and filter Change oil and filter; (perform a break-in oil
▶ change 100 H 6M 1000 (1600)
change at one month)
▶ Oil lines and fasteners 100 H 6M - Inspect for leaks and loose fittings
Front Gearcase oil (if
▶ equipped) 100 H 6M - Inspect level; change yearly
Middle Gearcase oil (if

Rear gearcase oil (if

▶ Transmission fluid 100 H 6M 1000 (1600) Change fluid

Cycle the key to prime and pressurize the fuel
D Fuel System 1000 (1600) system. Check for leaks at fuel cap, fuel line /
100 H 12 M
E rail, and fuel pump; Replace lines every 2 years
Radiator
▶ (if applicable) 100 H 12 M - Inspect; clean external surfaces
▶ Cooling Hoses 100 H 12 M - Inspect for leaks; clean external surfaces

▶ Engine mounts 100 H 12 M - Inspect
Exhaust muffler /pipe 100 H 12 M - Inspect
MAINTENANCE
HOUR- CALEN-
D Spark plug 1000 (1600) inspect; replace as needed
100 H 12 M
E
Inspect for wear, routing, security; apply
2
▶ Wiring 100 H 12 M - dielectric grease to connectors subjected to
water, mud, etc.
D Clutches 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
D Front wheel bearings 100 H 12 M - Inspect; replace as needed
D Brake fluid 200 H 24 M - Change every two years
Spark arrestor - 60 M - Clean out
D - 5000 (8000) Inspect; adjust
Valve clearance 500 H
E
Idle speed - Adjust as needed.
Inspect periodically; adjust when parts are
D Toe adjustment -
replaced
Auxiliary brake (if
D▶ - Inspect daily; adjust as needed
equipped)
Headlight aim - Adjust as needed
▶ = Perform these procedures more often for vehicles subjected to severe use.
E= Emission Control System Service (California)
D = Have an authorized POLARIS dealer perform these services.
*Service Note: Under extreme use, change demand drive fluid every 25 hours. "Extreme Use" is defined as constant
ADC operation on hilly or mountainous terrain, or if ADC is the primary mode of AWD operation.
MAINTENANCE
GREASE LUBRICATION POINTS

There is a grease fitting on the front propshaft yoke. Apply a maximum of 3 pumps of grease.
ITEM RECOMMENDED LUBE METHOD FREQUENCY

Grease before long periods
Grease fittings of storage, and after
Front Propshaft Yoke Polaris Premium U-Joint Grease (3 pumps maximum) pressure washing or
submerging the vehicle. **
Front A-Arm Polaris All Season Grease Locate fitting and grease. Semi-annually **
Rear A-Arm Polaris All Season Grease Locate fitting and grease Semi-annually **
Rear Stabilizer Bar
Bushings (If equipped Polaris All Season Grease Locate fitting and grease Semi-annually **
with grease fittings)
** Semi-annually or 50 hours of operation. Refer to Maintenance Schedule for additional information. Service more
often under severe conditions (i.e. operating in water or hauling heavy loads).
MAINTENANCE
COMPONENT QUICK REFERENCE

III. # ITEM LUBE REC. METHOD FREQUENCY*
Change after first month
or first 25 hours of
operation, 100 hours
Polaris PS-4 Performance Add oil to proper level on thereafter; Change more 2
1 Engine Oil
Synthetic 4-Cycle Oil dipstick often (25 hours) in
severe duty conditions or
short trip cold weather
operation
Check level daily,
Engine Coolant Maintain coolant level in change coolant every 2
2 Polaris 60/40 Coolant
coolant reservoir bottle. years
Maintain fluid level
Check level at pre-ride
between “MAX and
3 Brake Fluid Polaris DOT 4 Brake Fluid inspection; change fluid
“MIN” lines on the
every two years
master cylinder reservoir
* More often under severe use, such as operated in water or under severe loads.
MAINTENANCE
COMPONENT QUICK REFERENCE

# ITEM LUBE REC. METHOD FREQUENCY*
1 Change after 1st month or first
25 hours of operation, 100 hours
Polaris PS-4 Synthetic 4- Add oil to proper level on thereafter; Change more often
Engine Oil
Cycle Engine Oil dipstick (25 hours) in severe duty
conditions or short trip cold
weather operation
2 Polaris 50/50 Extended Maintain coolant level in Check level daily, change
Engine Coolant
Life Coolant coolant reservoir bottle. coolant every 2 years
3 Maintain fluid level between Check level during pre-ride
Polaris DOT 4 Brake “MAX and “MIN” lines on the inspection; change fluid every
Brake Fluid
Fluid master cylinder reservoir two years
*More often Under severe use, such as operated in water or under severe loads.
MAINTENANCE
# ITEM LUBE REC. METHOD FREQUENCY*

Add lubricant until it is visible Change fluid every 100 hours
4 Front Gearcase Polaris Demand Drive
at the fill hole threads r. or yearly
Polaris Full Synthetic Add lubricant into Fill Plug t Change fluid every 100 hours
5 Transmission until it is visible at the check
Gearcase Lubricant (AGL)
hole threads.
or yearly 2
** Oil Changes must be performed more often under severe use, such as operated in water or under severe loads.
4. Front Gearcase 5. Transmission
Fill Plug: 10–14 ft. lbs. (14–19 Nm)

Drain Plub: 10–14 ft. lbs. (14–19 Nm)
MAINTENANCE
SERVICE PRODUCTS AND LUBRICANTS

POLARIS LUBRICANTS, MAINTENANCE AND SERVICE PRODUCTS
PART NO. DESCRIPTION
2870791 Fogging Oil (12 oz. Aerosol)
2876244 PS-4 Syn. 4-Cycle Engine Oil (Quart)
Engine Lubricant 2876245 PS-4 Syn. 4-Cycle Engine Oil (Gallon / 3.8 l)
2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l)
2878919 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l)
2878068 AGL Gearcase Lubricant (1 Qt. / .95 l) (12 Count)
2878069 AGL Gearcase Lubricant (1 Gal. / 3.8 l) (4 Count)
Gearcase / Transmission 2878070 AGL Gearcase Lubricant (2.5 Gal. / 9.5 l) (2 Count)
Lubricants 2877922 Demand Drive fluid (Quart / .95 l)
2877923 Demand Drive fluid (2.5 Gallon / 9.5 l)
2870465 Oil Pump for 1 Gallon Jug
2880514 50/50 Extended Life 1 US Quart (0.9 L), 12 per case
Coolant 2880513 50/50 Extended Life 1 US Gallon (3.8 L), 4 per case
2880512 50/50 Extended Life 55 US Gallon Drum (208 L)
2871312 Grease Gun Kit
2871322 Premium All Season Grease (3 oz. cartridge) (24 Count)
2871423 Premium All Season Grease (14 oz. cartridge) (10 Count)
Grease / Specialized Lubricants 2871460 Premium Starter Grease
2871515 U-Joint Grease (3 oz.) (24 Count)
2871551 U-Joint Grease (14 oz.) (10 Count)
2871329 Dielectric Grease (Nyogel™)
2871326 Premium Carbon Clean (12 oz.) (12 count)
2870652 Fuel Stabilizer (16 oz.) (12 count)
2872189 DOT 4 Brake Fluid (12 count)
Miscellaneous 2871950 Loctite™ Threadlock 242 (6 ml.) (12 count)
2871956 Loctite™ 565 Thread Sealant
2871557 Crankcase Sealant, 3-Bond 1215 (5 oz.)
2859044 POLARIS Battery Tender™ Charger
NOTE
Each item can be purchased separately at your local
Polaris dealer.
NOTE
The number count indicated by each part number in the
table above indicates the number of units that are
shipped with each order.
MAINTENANCE
GENERAL MAINTENANCE
FRAME, NUTS, BOLTS, AND FASTENERS 5. Repeat Step 3 and Step 4 until the proper
Periodically inspect the torque of all fasteners in adjustment is made to the shift cable.
accordance with the maintenance schedule. Check that
all cotter pins are in place. Refer to specific fastener
torques listed in each chapter. 2
SHIFT CABLE INSPECTION
Shift cable adjustment is necessary when symptoms
include:
• Noise on deceleration
• Inability to engage a gear
• Excessive gear clash (noise)
• Gear selector is moving out of desired range
Inspect shift cable, clevis pins, and pivot bushings and

replace if worn or damaged
SHIFT CABLE ADJUSTMENT

NOTE
The shift cable should be adjusted at the rear
adjustment point near the transmission. If further
adjustment is needed, remove dash panel to access the
shift cable adjustment point under the shift lever.
1. Place gear selector in neutral. Make sure the

transmission bell crank is engaged in the neutral
position detent.
2. Locate the shift cable adjustment point at the engine-
to-transmission mount bracket.
3. With two open-end wrenches, loosen the outside jam
nut q counterclockwise. Turn outside jam nut 1 1/2
turns.
4. After turning the outside jam nut 1 1/2 turns, hold the
outside jam nut with a wrench and tighten the inside
jam w nut clockwise, until it is tight against the
bracket.
MAINTENANCE
STORAGE TIPS Oil and Filter

Stabilize the Fuel
Change the oil and filter.
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean Fuel Treatment or Air Filter/Air Box:
POLARIS Fuel Stabilizer. Follow the instructions on
the container for the recommended amount. Carbon 1. Inspect and clean (or replace) the pre-cleaner and air
filter.
Clean removes water from fuel systems, stabilizes
fuel and removes carbon deposits from pistons, rings, 2. Clean the air box.
valves and exhaust systems. 3. Drain the sediment tube.
3. Allow the engine to run for 15-20 minutes to allow the 4. Clean or replace the breather valve.
stabilizer to disperse through the entire fuel delivery
system.
Battery Storage:
Fog the Engine
1. After stabilizing the fuel, remove the spark plugs and Refer to Chapter 10 “Electrical” for off season storage
add 2-3 tablespoons of engine oil. To access the plug procedures.
holes, use a section of clear 1/4” hose and a small
plastic squeeze bottle filled with the pre-measured Clean the Exterior:
amount of oil.
Make any necessary repairs and clean the vehicle as
2. Reinstall the spark plugs. Torque to specification.
recommended.
3. Apply dielectric grease to the inside of the spark plug
cap and reinstall the caps onto the plugs. Storage Area/Covers:
4. Turn the engine over several times using electric
start. Oil will be forced in and around the piston rings Set the tire pressure and safely support the ATV with the
and ring lands, coating the cylinder with a protective tires slightly off the ground. Be sure the storage area is
film of fresh oil. well ventilated. Cover the vehicle with a genuine
5. If POLARIS fuel system additive is not used, the fuel POLARIS cover. Do not use plastic or coated materials.
tank, fuel lines, and injectors should be completely They do not allow enough ventilation to prevent
drained of gasoline. condensation, and may promote corrosion and oxidation.
NOTICE
Starting the engine during the storage period will disturb
the protective film created by fogging and damage
could occur. Never start the engine during the storage
period.
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as

recommended in the Periodic Maintenance Chart.
Fluid Levels
Inspect the fluid levels. Add or change fluids as

recommended in the Periodic Maintenance Chart.
• Demand drive unit (front gearcase)
• Rear gearcase (if equipped)
• Transmission
• Brake fluid (change every two years and any time the
fluid looks dark or contaminated)
• Coolant (test strength/fill)
MAINTENANCE
FUEL SYSTEM AND AIR INTAKE

FUEL SYSTEM VENT LINES
1. Check fuel tank vent line for signs of wear,
WARNING deterioration, damage or leakage. Replace every two
Gasoline is extremely flammable and explosive under years.
certain conditions. 2. Be sure vent line is routed properly and secured with 2
Always stop the engine and refuel outdoors or in a well cable ties. CAUTION: Make sure line is not
ventilated area. obstructed.
Do not smoke or allow open flames or sparks in or near THROTTLE PEDAL INSPECTION
the area where refueling is performed or where
This vehicle is equipped with Pedal Position Sensor q
gasoline is stored.
used to detect when the throttle pedal w is pushed or
Do not overfill the tank. Do not fill the tank neck. released.
If you get gasoline in your eyes or if you swallow
gasoline, seek medical attention immediately. Do not
induce vomiting.
If you spill gasoline on your skin or clothing,
immediately wash it off with soap and water and
change clothing.
Never start the engine or let it run in an enclosed area.
Engine exhaust fumes are poisonous and can result
loss of consciousness or death in a short time.
Never drain the fuel when the engine is hot. Severe
burns may result.
FUEL LINES
1. Check fuel lines for signs of wear, deterioration,
damage or leakage. Replace if necessary. The throttle pedal should move freely and always return
2. Be sure fuel lines are routed properly and secured back to its idle position when released.
with cable ties. CAUTION: Make sure lines are not Check throttle pedal periodically.
kinked or pinched.
3. Replace all fuel lines every two years. AIR FILTER SERVICE
FUEL PUMP / FILTER It is recommended that the air filter be replaced annually.
The fuel pump components on the RANGER are not When riding in extremely dusty or wet conditions, or at
serviceable. If a component requires replacement, the wide open throttle for extended periods, replacement is
fuel pump assembly must be replaced. required more often.
The filter should be inspected periodically before each
NOTE ride, using the following procedure.
See the “Online Electronic Parts Catalog” for correct Removal
parts information. 1. Lift the rear cargo box to access the airbox cover.
For all other information related to the Fuel System,
refer to Chapter 4.
MAINTENANCE
2. Unhook the two clips q from airbox cover and 4. Clean airbox of any oil or water deposits and apply a
remove cover. Inspect the cover seal. It should small amount of grease to the sealing surfaces of the
adhere tightly to the cover. filter.
5. Reinstall the air filter into the airbox container. Be
sure the filter fits tightly in the air box and engage the
(2) clips.
ENGINE AIR INTAKE INSPECTION

1. Remove the cover from the outer side of the seat
base q and remove the pre-filter element.
3. Remove the air filter assembly. Inspect the air filter

and replace if necessary.
NOTE
If the filter has been soaked with fuel or oil it must be
replaced. Do not attempt to wash the air filter. If
cleaning is required, replace the filter.
2. If the pre-filter element is dirty, clean it with hot,

soapy water. Rinse and dry the filter element
thoroughly. Inspect element for tears or damage.
Replace if necessary.
3. Reinstall the pre-filter element into the seat frame
and install the cover.
PVT AIR INTAKE INSPECTION

1. Remove the PVT intake cover q.
REF. DESCRIP- NOTES

TION
w Cover
e Filter
r Seal
t Clamp
2. Verify there is no debris obstructing the airway.
y Airbox
3. Reinstall the cover.
u Boot
Installation
MAINTENANCE
ENGINE COMMON
COMPRESSION AND LEAKDOWN TEST
NOTE
This Polaris 4-Stroke engine is equipped with an
automatic decompressor. Compression readings will 2
vary in proportion to cranking speed during the test.
Average compression (measured) is about 80-120 psi
during a compression test.
Smooth idle generally indicates good compression. Low

engine compression is rarely a factor in running condition
problems above idle speed. Abnormally high
compression can be caused by a decompressor
malfunction, or worn or damaged exhaust cam lobes.
Inspect camshaft and automatic decompression
mechanism if compression is abnormally high.
A cylinder leakage test is the best indication of engine
condition on models with automatic decompression.
Follow manufacturer’s instructions to perform a cylinder
leakage test (never use high pressure leakage testers as
crankshaft seals may dislodge and leak).
Cylinder Compression
80 - 120 PSI
Cylinder Leakage
Service Limit: 10%
Inspect for cause if leakage exceeds 10%
MAINTENANCE
ENGINE - 325
ENGINE OIL LEVEL CHECK - 325 6. Add the recommended fluid as needed to the upper
Access the oil dipstick and fill tube from the right side of oil fill . Maintain the oil level in the safe range
the vehicle. A rising oil level between checks in cool between the FULL and ADD marks. Do not overfill.
weather driving can indicate contaminants such as gas
or moisture collecting in the crankcase. If the oil level is
over the full/safe mark, change the oil immediately.
IMPORTANT
Allowing dirt or debris to enter the engine can result in
serious engine damage. Always clean away all dirt and
debris from the dipstick area before removing the
dipstick.
1. Position the vehicle on a level surface.

2. Place the transmission in PARK.
3. Always clean away all dirt and debris from the area
around the dipstick and fill cap before removing.
Remove the dipstick. Wipe it dry with a clean cloth.
4. Reinstall and tighten the dipstick. 7. Reinstall and tighten the dipstick.
5. Remove the dipstick and check the oil level.
NOTE
Rising oil level between checks in cool weather driving,
can indicate moisture collecting in the oil reservoir. If
the oil level is over the full mark, change the oil.
MAINTENANCE
ENGINE OIL AND FILTER CHANGE - 325 10. Remove the cover (item 5). The oil filter (item 6*) may
Always change the engine oil when engine is at or may not come out with the cover. If the filter stays
operating temperature. inside the engine, pull it out after removing the cover.
1. Position the vehicle on a level surface. Place the

transmission in PARK.
2. Start the engine. Allow it to idle for two to three 2
minutes. Stop the engine.
3. Clean the area around the drain plug.
CAUTION
Hot oil can cause burns to skin. Do not allow hot oil to
contact skin.
4. Place a drain pan beneath engine crankcase at the

rear of the vehicle and remove the drain plug (item 1)
/ sealing washer (Item 2).
11. Using a clean dry cloth, clean the surface of the
crankcase.
12. A spring (item 7) is located inside the oil filter cavity. It
may or may not come out with filter. If it comes out
with the filter, reinstall it over the fitting (item 9).
5. Allow the oil to drain completely.

6. Install a new sealing washer (item 2) onto the drain
plug (item 1).
NOTE
The sealing surfaces on drain plug and crankcase
should be clean and free of burrs, nicks or scratches.
7. Reinstall the drain plug (item 1). Torque to

specification.
TORQUE
Oil Pan Drain Plug:
12 ft-lb (17 Nm)
8. Using a clean dry cloth, clean the oil filter cover (item
5)and surrounding area on the crankcase.
9. Place shop towels beneath the filter cover to catch oil
drips. Remove the cover screws (item 3).
MAINTENANCE
13. Properly dispose the used oil filter. Inspect the cover VALVE CLEARANCE INSPECTION - 325
(Item 4) O-ring (Item 3). Replace if worn or damaged.
Note the orientation text on the new oil filter (Item 2) NOTE
as shown. The oil filter must be installed correctly to
Valve clearance inspection should be performed on a
prevent severe engine damage.
cold engine, at room temperature.
1. Remove the seats and disconnect the negative (-)

battery cable.
2. Remove the PVT cover and ducting tubes.
3. Remove the following components:
IMPORTANT
Oil flows through the filter and into the cover. Keep
cover ports free from foreign material.
14. Verify the oil filter spring is installed inside the filter
cavity. Lubricate the O-ring with clean engine oil. 1 – Spark Plug Wire / Spark Plug
15. Install the new oil filter onto the cover fitting in the 2 – Valve Cover Screws
correct orientation. Install the filter/cover assembly
into the bore. Torque the screws to specification. 3 – Grommets
TORQUE 4 – Valve Cover
Oil Filter Cover: NOTE

88 in. lbs. (10 Nm) It may be necessary to tap the cover lightly with a soft-
faced hammer to loosen it from the cylinder head.
16. Fill the sump with 1.75 quarts (1.65 l) of the
recommended oil. NOTE
17. Reinstall the upper fill cap (if removed) and tighten
Discard valve cover Isolators upon removal. New
the dipstick.
Isolators are required once removed.
18. Make sure the transmission is in PARK. Apply the
brakes. Inspect the valve cover gasket and replace if damaged
19. Start the engine. Allow it to idle for one to two or signs of leaking are present.
minutes.
20. Stop the engine. Inspect for leaks. 4. Remove the outer PVT cover and drive belt as shown
in chapter 6.
NOTE
5. The engine will need to be rotated using the drive
Re-check the oil level on the dipstick and add oil as clutch to inspect all four valve clearances.
necessary to bring the level to the upper mark on the
dipstick. 6. Rotate the drive clutch until the intake and exhaust
cam lobes face away from each other as shown.
21. Dispose of used filter and oil properly.
MAINTENANCE
MEASUREMENT
Intake Valve Clearance (cold):
.005 ± .002″ (0.125 ± 0.05 mm)
Exhaust Valve Clearance (cold):

.014 ± .002″ (0.350 ± 0.05 mm) 2
9. Record the results of each measurement for future
reference.
10. If the valve clearances are out of specification,
proceed to “Valve Clearance Adjustment”. See Valve
Clearance Check / Adjustment, page 3.68
11. If previously removed, reinstall the spark plug. Torque
7. When the cams are at TDC, the I’s on the intake cam spark plug to specification.
sprocket and E’s on the exhaust cam sprocket will be
TORQUE
inline with the cylinder head deck as shown.
Spark Plug Torque:
9 ft-lbs (12 Nm)w/o anti-seize
12. Inspect the valve cover seal and replace if necessary.

13. Install NEW isolators on the valve cover bolts. Install
the valve cover and the four T40 bolts. Torque bolts to
specification.
TORQUE
Valve Cover Bolts:
7 ft-lbs (10 Nm)
14. Install the spark plug wire. Ensure wire is pushed

down all the way so it fully engages the spark plug.
8. Measure the valve clearance between the intake and 15. Install drive belt and outer clutch cover and (8)
exhaust lobes and tappets using a feeler gauge. retaining screws (see PVT System). Torque to
Compare results to the specifications. specification.
MAINTENANCE
TORQUE
Outer Clutch Cover Screws:
45-50 in-lbs (5 Nm)
16. Connect the negative (-) battery cable to the battery.

17. Reinstall PVT cover and ducting.
18. Lower the Tilt bed.
19. Start the engine to ensure proper operation.
ENGINE BREATHER - 325

IMPORTANT
Operation of the vehicle without breather hoses or
breather box can cause engine damage. Always
reinstall a breather hoses after removing for service.
1. Remove the hose clamps from the engine valve cover

and breather box. Remove the hose.
2. Remove the hose clamps from the air box and
breather box. Remove the hose.
3. Inspect the hoses for debris. Blow gently through the
hoses to check for clogging. Replace a damaged or
clogged hose.
4. Check the hoses for cracks, deterioration, abrasions
or leaks. Replace as needed.
5. Reinstall the hoses and clamps.
MAINTENANCE
ENGINE
ENGINE OIL LEVEL - 570 OIL AND FILTER CHANGE - 570
Access the oil dipstick and fill tube from the right side of Always change the oil and filter at the intervals outlined in
the vehicle. A rising oil level between checks in cool the Periodic Maintenance Chart. Always change the oil
weather driving can indicate contaminants such as gas filter whenever changing oil.
or moisture collecting in the crankcase. If the oil level is 2
over the full/safe mark, change the oil immediately. Oil Filter Torque:
Turn by hand until filter gasket contacts sealing
surface, then turn an additional 3/4 turn
Oil Filter Wrench:

PV-50105
Recommended Engine Oil:

Polaris PS–4
Synthetic 5W-50
NOTICE: Care must be taken to ensure that the fluids

are contained. Be prepared to collect the fluid with
suitable containers before opening any compartment
or disassembly of any component containing fluids.
1. Set machine on a level surface.
2. Clean the area around the dip stick. CAUTION
3. Remove dipstick and wipe dry with a clean cloth. Personal injury can occur when handling used oil. Hot
oil can cause burns or skin damage.
4. Reinstall dipstick completely.
NOTE 1. Place vehicle on a level surface.

The dipstick must be screwed completely in to ensure 2. Place the transmission in PARK (P).
accurate measurement.
3. Clean area around drain plug at bottom of oil pan.
4. Start the engine. Allow it to warm up at idle for two to
three minutes.
5. Stop the engine.
6. Place a drain pan under the crank case.
7. Remove the drain plug q. Allow oil to drain
completely.
5. Remove dipstick and check the oil level. The oil level
should be between the top line and the bottom line
on the dipstick. Add oil as indicated by the level on
the dipstick. Do not overfill.
NOTE
Rising oil level between checks in cool weather driving,
can indicate moisture collecting in the oil reservoir. If
the oil level is over the full mark, change the oil.
MAINTENANCE
8. Replace sealing washer on drain plug. VALVE CLEARANCE - DOHC

Inspect and adjust valve clearance while the engine is
NOTE
cold and the piston positioned at Top Dead Center (TDC)
The sealing surfaces on the drain plug and the oil tank on compression stroke.
should be clean and free of burrs, nicks or scratches.
1. Tilt the cargo box.
9. Reinstall the drain plug and torque it to specification. 2. Remove the spark plug high tension lead q and
remove the spark plug w. CAUTION: Place a clean
TORQUE shop towel into the spark plug cavity to prevent dirt
from entering.
Engine Oil Plug:
14 ft-lbs (19 Nm)
10. Place a drain pan under the oil filter.

11. Place shop towels beneath oil filter (Item 2). Use Oil
Filter Wrench (PV-50105), turn filter counterclockwise
to remove.
12. Using a clean dry cloth, clean filter sealing surface on
the crankcase.
13. Lubricate the o-ring on new filter with a thin film of
engine oil. Check to make sure the O-ring is in good
condition.
14. Install the new filter and turn it by hand until the filter
gasket contacts the sealing surface, then turn an
additional 3/4 of a turn. 3. Remove the valve cover bolts e, cover r and
15. Remove dipstick. gasket.
16. Add oil as necessary to bring the oil level to the upper NOTE
mark on the dipstick. Do not over fill the engine, the
maximum oil capacity is 2 qts(1.9 l). It may be necessary to tap the cover lightly with a soft-
faced hammer to loosen it from the cylinder head.
NOTE
The dipstick must be screwed completely in to ensure NOTE
accurate measurement.
Isolators must be replaced after each use.
17. Reinstall the upper fill cap (if removed) and tighten
4. Remove the PVT cover to access the drive clutch.
the dipstick.
18. Place the transmission in PARK (P).
19. Verify that the transmission is still positioned in PARK
(P).
20. Start the engine. Allow it to idle for two minuets.
21. Stop the engine and check for leaks.
22. Check the oil level on the dipstick and add oil as
necessary to bring the level to the upper mark on the
dipstick.
23. Dispose of used filter and oil properly.
MAINTENANCE
5. Use drive clutch to rotate the crankshaft until the cam BREATHER VALVE INSPECTION
chain sprocket timing marks are aligned with the This engine is equipped with a breather valve q. The
gasket surface as shown. valve is located on the front of the engine. The valve
should only allow air to pass from the engine to the
breather hose w and finally to the intake e and NOT
from the air intake to the engine. Replace as necessary.
2
IMPORTANT
Intake cam sprocket should have “I” marks aligned with
the gasket surface and the exhaust cam sprocket
should have “E” marks aligned with the gasket surface.
6. Measure the valve clearance of each valve using a

feeler gauge. Record the measurement if clearance
is out of specification.
MEASUREMENT
Intake Valve Clearance:
0.006 ± 0.002" (0.15 ± 0.05 mm)
Exhaust Valve Clearance:

0.008 ± 0.002" (0.20 ± 0.05 mm)
BREATHER HOSE
Be sure breather line is routed properly and secured in
place.
CAUTION
Make sure line(s) are not kinked or pinched.
MAINTENANCE
TRANSMISSION AND GEARCASES

TRANSMISSION LUBRICATION 7. Remove the drain plug and allow lubricant to drain
completely.
NOTE
NOTE
It is important to follow the transmission maintenance
intervals described in the Periodic Maintenance Chart. On some 2012 vehicles, a commercially available long
Regular fluid level inspections should be performed as ball end hex bit socket may be needed to remove the
well. drain plug.
The transmission lubricant level should be checked and 8. Clean the drain plug magnetic surface. Reinstall
changed in accordance with the maintenance schedule. drain plug with a new O-ring and torque to
• Be sure vehicle is positioned on a level surface when specification.
checking or changing the lubricant. 9. Add the recommended amount of lubricant through
• Check vent hose to be sure it is routed properly and the fill plug hole. Maintain the lubricant level at the
unobstructed. bottom of the fill plug hole when filling the
transmission. Do not overfill.
Transmission Lubricant Level Check
Maintain the fluid level even with the bottom threads of
the fill plug hole.
1. Position vehicle on a level surface.
2. Remove the fill / check plug q and check the
lubricant level.
REF. DESCRIP- NOTES

TION
w Fill Plug 14 ft-lbs (19
Nm)
e Drain Plug 14 ft-lbs (19

3. If lubricant level is not level with the bottom threads, Nm)
add the recommended lubricant as needed. Do not
overfill.
FLUID CAPACITY
4. Reinstall the fill plug and torque to specification.
Recommended Transmission Lubricant:
TORQUE Full Synthetic AGL (PN 2878068) (Quart)
Capacity: 41 oz. (1200 ml)
Transmission Drain / Fill Plug:
14 ft-lbs (19 Nm)
10. Reinstall fill plug with a new O-ring and torque to
specification.
Transmission Lubricant Change
Access the drain plug from underneath the vehicle TORQUE
through the access hole in the skid plate. Transmission Drain / Fill Plug:
5. Remove the fill plug (refer to “Transmission Lubricant 14 ft-lbs (19 Nm)
Level Check”).
11. Check for leaks. Dispose of used lubricant properly.
6. Place a drain pan under the transmission drain plug.
MAINTENANCE
FRONT GEARCASE LUBRICATION 8. Remove the drain plug and allow fluid to drain
completely.
NOTE
It is important to follow the front gearcase maintenance
intervals described in the Periodic Maintenance Chart.
Regular fluid level inspections should be performed as
well. 2
The front gearcase fluid level should be checked and
changed in accordance with the maintenance schedule.
• Be sure vehicle is positioned on a level surface when
checking or changing the fluid.
• Check vent hose to be sure it is routed properly and
unobstructed.
Front Gearcase Fluid Level Check
The fill plug is located on the front-right side of the front
gearcase. Access the fill plug from the side of the 9. Clean the drain plug magnetic surface.
vehicle. Maintain the fluid level even with the bottom
10. Reinstall drain plug with a new O-ring and torque to
threads of the fill plug hole.
specification.
1. Position vehicle on a level surface.
11. Add the recommended amount of fluid through the fill
2. Open the hood to gain access to the gearcase area. hole. Maintain the fluid level even with the bottom
threads of the fill plug hole.
3. Remove the fill plug q and check the fluid level.
FLUID CAPACITY
Recommended Front Gearcase Fluid:
Polaris Demand Drive
(PN 2877922) (Quart)
Capacity: 6.7–7.6 oz. (200–225 ml)
12. Reinstall fill plug with a new O-ring and torque to

specification.
TORQUE
Front Gearcase Drain / Fill Plug:
10 ft-lbs (14 Nm)
13. Check for leaks. Dispose of used fluid properly.

4. If fluid level is not even with the bottom threads, add
the recommended fluid as needed. Do not overfill.
5. Reinstall the fill plug and torque to specification.
TORQUE
Front Gearcase Drain / Fill Plug:
10 ft-lbs (14 Nm)
Front Gearcase Fluid Change:

The drain plug is located on the bottom side of the
front gearcase. Access the drain plug through the
skid plate.
6. Remove the fill plug q (refer to “Front Gearcase
Fluid Level Check”).
7. Place a drain pan under the front gearcase drain
plug w.
MAINTENANCE
COOLING SYSTEM
COOLING SYSTEM OVERVIEW COOLANT LEVEL INSPECTION
The engine coolant level is controlled, or maintained, by The recovery bottle q and radiator pressure cap w are
the recovery system. The recovery system components located under the hood.
are the recovery bottle, radiator filler neck, radiator
pressure cap and connecting hose.
As coolant operating temperature increases, the
expanding (heated) excess coolant is forced out of the
radiator past the pressure cap and into the recovery
bottle. As engine coolant temperature decreases the
contracting (cooled) coolant is drawn back up from the
bottle, past the pressure cap, and into the radiator.
NOTE
Some coolant level drop on new vehicles is normal as
the system is purging itself of trapped air. Observe
coolant level often during break-in period.
CAUTION With the engine at operating temperature, the coolant

Overheating of engine could occur if air is not fully level should be between the “MAX” and “MIN” marks on
purged from system. the recovery bottle. If not, perform the following:
Polaris recommends the use of Polaris 50/50 Extended
Life Antifreeze or a 50/50 mixture of high quality 2. The coolant level must be maintained between the
aluminum compatible anti-freeze/coolant and distilled “MAX” and “MIN” levels indicated on the recovery
water. bottle
NOTE
Polaris 50/50 Extended Life Antifreeze is already
premixed and ready to use. Do not dilute with water.
3. If the coolant level is below the “MIN” mark, open the

hood to access the radiator pressure cap and
recovery bottle cap.
NOTE
If overheating is evident, allow system to cool
completely and check coolant level in the radiator and
inspect for signs of trapped air in system.
MAINTENANCE
WARNING
Never remove the pressure cap when the engine is
warm or hot. Escaping steam can cause severe burns.
The engine must be cool before removing the pressure
cap.
2
4. Remove the pressure cap. Using a funnel, add
coolant to the top of the radiator filler neck.
5. Reinstall the pressure cap.
NOTE
Use of a non-standard pressure cap will not allow the
recovery system to function properly.
6. Remove the recovery bottle cap.

7. Fill the recovery bottle to the “MAX” mark with Polaris
Premium 50/50 Anti-Freeze/Coolant or a 50/50
mixture of antifreeze/coolant and distilled water as
required for freeze protection in your area.
8. Reinstall the recovery bottle cap.
9. If coolant was required, start engine and check for
leaks. Make sure radiator fins are clean to prevent
overheating.
MAINTENANCE
50/50 EXTENDED-LIFE ENGINE ANTIFREEZE

Beginning in the later part of 2014, Polaris began using 50/50 Extended Life antifreeze in some vehicles. All model-
year 2015 and newer vehicles will use 50/50 Extended Life antifreeze.
Using the 50/50 Extended-life antifreeze extends the service interval from two to five years.
It is important to note that 60/40 antifreeze can be mixed with 50/50 Extended Life antifreeze, however, mixing the two
will not extend the service interval. To receive the full five year service interval benefit, the vehicles’s entire cooling
system must be drained and replenished with the new 50/50 Extended Life antifreeze.
To quickly determine if a vehicle is using 60/40 or 50/50 Extended Life antifreeze, simply note the color of the coolant.
60/40 antifreeze will be green, while 50/50 Extended Life antifreeze will be yellow.
50/50 EXTENDED- LIFE ANTIFREEZE PART NUMBERS
PART NUMBERS DESCRIPTION
2880514 1 US Quart (0.9 L) / 12 per case
2880513 1 US Gallon (3.8 L) / 6 per case
2880512 55 US Gallon Drum (208 L)
MAINTENANCE
COOLANT STRENGTH / TYPE COOLING SYSTEM HOSES

Test the strength of the coolant using an antifreeze
hydrometer.
• A 50/50 or 60/40 mixture of antifreeze and distilled

water will provide the optimum cooling, corrosion
protection, and freeze protection.
• Do not use tap water, straight antifreeze, or straight
water in the system. Tap water contains minerals and
impurities which build up in the system. Straight water
or antifreeze may cause the system to freeze, corrode,
or overheat. REF DESCRIPTION
FLUID CAPACITY q Clamp
Recommended Anti-Freeze/Coolant:
w Hose to Thermostat
Polaris 50/50 Anti-Freeze/Coolant
2871534 (Quart) e Radiator
r Recovery Bottle
t Hose to Water Pump
y Retainer
u Bolt
1. Inspect all hoses for cracks, deterioration, abrasion

or leaks. Replace if necessary.
2. Check tightness of all hose clamps.
CAUTION
Do not over-tighten hose clamps at radiator, or radiator
fitting may distort.
TORQUE
Radiator Hose Clamp:
36 in-lbs (0.4 Nm)
MAINTENANCE
RADIATOR INSPECTION / CLEANING COOLANT DRAIN / RADIATOR REMOVAL

1. Allow the vehicle to cool down if recently operated.
2. Place a suitable drain pan underneath the right hand
side of the radiator.
3. Open the hood and slowly open the radiator
pressure cap to relieve system pressure.
WARNING
Never remove the pressure cap when the engine is
warm or hot. Escaping steam can cause severe burns.
The engine must be cool before removing the pressure
cap.
4. Open the drain valve q on the front side of the

radiator and allow the coolant to completely drain.
Properly dispose of the used coolant.
REF DESCRIPTION
q Fan Motor
w Shroud
e Radiator
1. Check radiator air passages for restrictions or

damage.
2. Carefully straighten any bent radiator fins.
3. Remove any obstructions with compressed air or low
pressure water.
CAUTION
Washing the vehicle with a high-pressure washer could
damage the radiator fins and impair the radiators 5. Remove the screws that retain the recovery bottle to
effectiveness. Use of a high-pressure washer is not the frame bracket. Set the recovery bottle out of the
recommended. way.
MAINTENANCE
6. Remove the upper and lower coolant lines from the Installation
radiator.
11. Reverse previous procedures for installation.
12. Upon installation, be sure the lower radiator mounts
are placed properly in the frame support.
7. Remove the recovery bottle return line.

8. Remove the two mounting screws w that secure the
upper portion of the radiator to the frame.
13. After the radiator is installed, verify the rubber
mounts e have remained in place.
14. After installation and reassembly, remove the
pressure cap and fill the radiator and recovery bottle
with coolant.
15. Refer to the cooling system bleeding procedure in
Chapter 3, under “Engine Installation Notes”.
9. Carefully lift the radiator straight up and out of the

vehicle. Take care not to damage the cooling fins.
10. Remove the four bolts that retain the fan motor and
shroud to the radiator.
MAINTENANCE
FINAL DRIVE / WHEEL AND TIRE

WHEEL AND HUB TORQUE TABLE WHEEL REMOVAL
ITEM SPECIFICATION
Torque: Steel Wheels:
36 ft-lbs (49 Nm)
Wheels Nuts Aluminum Wheels:
30 ft-lbs + 90º (41 Nm +
90º)
Front Hub Nut 90 ft-lbs (122 Nm)
Rear Hub Nut 110 ft-lbs (150 Nm)
CV SHAFT BOOT INSPECTION

Inspect the CV shaft boots in the front and rear for
damage, tears, wear, or leaking grease. If the rubber
boot exhibits any of these symptoms, replace the boot. RE- DESCRIP- NOTES
Refer to Final Drive for CV boot replacement. F. TION
q Wheel Nuts Torque: Steel Wheels:
36 ft-lbs (49 Nm)
Aluminum Wheels:
30 ft-lbs + 90º (41 Nm + 90º)
w Washers
1. Stop the engine, place the transmission in gear and

chock wheels.
2. Loosen the wheel nuts slightly.
3. Elevate the side of the vehicle by placing a suitable
stand under the footrest frame.
4. Remove the wheel nuts and washers and remove
the wheel.
MAINTENANCE
WHEEL INSTALLATION TIRE PRESSURE

1. With the transmission in gear and wheels chocked,
place the wheel in the correct position on the wheel CAUTION
hub. Be sure the valve stem is toward the outside Maintain proper tire pressure.
and rotation arrows on the tire point toward forward Refer to the warning tire pressure decal applied to the
rotation. vehicle.
2. Attach the washers (if applicable) and wheel nuts
2
and finger tighten them. TIRE PRESSURE INSPECTION (PSI - COLD)
3. Lower the vehicle to the ground.
325 ETX 570 EFI 570 EFI CREW
4. Tighten wheel nuts to specification. Steel: 27 ft-lbs
(37 Nm) 10 PSI Front 10 PSI Front 14 PSI Front
Aluminum: 30 ft-lbs (41 Nm) + 1/4 Turn 10 PSI Rear 12 PSI Rear 16 PSI Rear
CAUTION
If wheels are improperly installed it could affect vehicle
handling and tire wear. On vehicles with tapered wheel
nuts, make sure the tapered end of the nut goes into
the taper on wheel.
TIRE INSPECTION
• Improper tire inflation may affect vehicle
maneuverability.
• When replacing a tire always use original equipment
size and type.
• The use of non-standard size or type tires may affect
vehicle handling.
MEASUREMENT
Tire Lug Service Limit:
Replace if 1/8″ (3 mm) or less.
WARNING
Operating with worn tires will increase the possibility of
the vehicle skidding easily with possible loss of control.
Worn tires can cause an accident. Always replace tires
when the usable tread depth has worn out.
MAINTENANCE
ELECTRICAL AND IGNITION SYSTEM

BATTERY MAINTENANCE BATTERY FLUID LEVEL (CONVENTIONAL
Keep battery terminals and connections free of BATTERY)
corrosion. If cleaning is necessary, remove the corrosion A poorly maintained battery will deteriorate rapidly.
with a stiff wire brush. Wash with a solution of one Check the battery fluid level often. Maintain the fluid level
tablespoon baking soda and one cup water. Rinse well between the upper q and lower level w marks.
with tap water and dry off with clean shop towels. Coat
the terminals with dielectric grease or petroleum jelly.
Be careful not to allow cleaning solution or tap water into
the battery.
WARNING
CALIFORNIA PROPOSITION 65 WARNING:
Batteries, battery posts, terminals and related
accessories contain lead and lead compounds, and
other chemicals known to the State of California to
cause cancer and birth defects or other reproductive
harm.
WASH HANDS AFTER HANDLING.
WARNING
Add only distilled water. Tap water contains minerals that
Battery electrolyte is poisonous. It contains sulfuric are harmful to a battery.
acid. Serious burns can result from contact with skin,
eyes or clothing. Antidote:
BATTERY REMOVAL
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow 1. Remove the seat to access the battery area.
with milk of magnesia, beaten egg, or vegetable oil. Call 2. Remove the two T-27 Torx screws q retaining the
physician immediately. battery bracket to the battery box.
Eyes: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases.
Keep sparks, flame, cigarettes, etc. away.
Ventilate when charging or using in an enclosed space.
Always shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
NOTE
Batteries must be fully charged before use or battery
life will be reduced by 10-30% of full potential. Charge
battery for 3-5 hours at a current equivalent of 1/10 of
the battery’s rated amp/hour capacity. Do not use the
alternator to charge a new battery.
3. Disconnect the black (-) (negative) battery cable.
4. Disconnect the red (+) (positive) battery cable.
5. Lift the battery out of the vehicle, being careful not to
tip and spill electrolyte.
CAUTION
To reduce the chance of sparks: Whenever removing
the battery, disconnect the negative (black) cable first.
When reinstalling the battery, install the negative cable
last.
MAINTENANCE
BATTERY INSTALLATION SPARK PLUG SERVICE - 570

Using a new battery that has not been fully charged can 1. Remove spark plug high tension lead q. Clean plug
damage the battery and result in a shorter life. It can also area so no dirt and debris can fall into engine when
hinder vehicle performance. Follow the battery charging plug is removed.
procedure before installing the battery.
1. Ensure that the battery is fully charged. 2
2. Place the battery in the battery holder.
3. Install the battery vent tube and route it down
through the battery box.
NOTE
Route vent tube to prevent electrolyte from damaging
critical components (i.e. wire harness, brake lines,
throttle cable).
4. Coat the terminals with dielectric grease or

petroleum jelly.
5. Connect and tighten the red (+) (positive) cable first. 2. Remove spark plug w.
6. Connect and tighten the black (-) (negative) cable 3. Inspect electrodes for wear and carbon buildup w.
last. Look for a sharp outer edge with no rounding or
7. Verify that cables are properly routed and install the erosion of the electrodes.
hold-down strap.
BATTERY STORAGE
Whenever the vehicle is not used for a period of three
months or more, remove the battery from the vehicle,
ensure that it's fully charged, and store it out of the sun in
a cool, dry place. Check battery voltage each month
during storage and recharge as needed to maintain a full
charge.
NOTE
Battery charge can be maintained by using a Polaris
battery tender charger or by charging about once a
month to make up for normal self-discharge. Battery
tenders can be left connected during the storage 4. Clean with electrical contact cleaner or a glass bead
period, and will automatically charge the battery if the spark plug cleaner only.
voltage drops below a pre-determined point.
CAUTION
A wire brush or coated abrasive should not be used.
BATTERY CHARGING
1. Remove the battery from the vehicle to prevent
damage from leaking or spilled electrolyte during
charging.
2. Charge the battery with a charging output no larger
than 1/10 of the battery’s amp/hr rating. Charge as
needed to raise the specific gravity to 1.270 or
greater.
3. Reinstall the battery.
MAINTENANCE
5. Measure gap with a wire gauge. Refer to MAIN FRAME/ENGINE GROUND

specifications in picture below for proper spark plug Inspect engine ground cable connections q. Be sure
type and gap. Adjust gap if necessary by bending the ground wires are tight and not corroded. The main
side electrode carefully. chassis ground can be found below the fuse box under
the driver’s seat base.
Spark Plug Gap:

0.028 - 0.032″ (0.7 - 0.8 mm)
6. If necessary, replace spark plug with proper type.
CAUTION
Severe engine damage may occur if the incorrect spark
plug is used.
7. Install spark plug and torque to specification.

Recommended Spark Plug:
NGK MR7F
TORQUE
Spark Plug:
MAINTENANCE
STEERING
STEERING INSPECTION NOTE TIE ROD END / STEERING INSPECTION
The steering components should be checked periodically • To check for play in the tie rod end, grasp the steering
for loose fasteners, worn tie rod ends, and damage. Also tie rod, pull in all directions feeling for movement.
check to make sure all cotter pins are in place. If cotter • Replace any worn steering components. Steering
pins are removed, they must not be re-used. Always use should move freely through entire range of travel 2
new cotter pins. without binding.
Replace any worn or damaged steering components.
Steering should move freely through entire range of
travel without binding. Check routing of all cables, hoses,
and wiring to be sure the steering mechanism is not
restricted or limited.
NOTE
Whenever steering components are replaced, check
front end alignment. Use only genuine Polaris parts.
WARNING
Due to the critical nature of the procedures outlined in
this chapter, Polaris recommends steering component
repair and adjustment be performed by an authorized
Polaris MSD-certified technician when replacing worn Elevate front end of machine so front wheels are off
or damaged steering parts. the ground. Check for any looseness in front hub/
Use only genuine Polaris replacement parts. wheel assembly by grasping the tire firmly at top and
bottom first, and then at front and rear. Try to move the
wheel and hub by pushing inward and pulling outward.
• If abnormal movement is detected, inspect the hub and

wheel assembly to determine the cause (loose wheel
nuts or loose front hub nut).
• Refer to the Steering/Suspension or Final Drive
chapter for more information.
MAINTENANCE
WHEEL TOE ALIGNMENT INSPECTION 5. Again measure the distance between the marks and
1. Place machine on a smooth level surface and set record. Call this measurement “B” w. Subtract
steering wheel in a straight ahead position. Secure measurement “B” from measurement “A”. The
the steering wheel in this position. difference between measurements “A” and “B” is the
vehicle toe alignment. The recommended vehicle toe
tolerance is 1/8” to 1/4”, (.3 to .6 cm) toe out. This
means the measurement at the front of the tire (A) is
1/8” to 1/4” (.3 to .6 cm) wider than the measurement
at the rear (B).
MEASUREMENT
Wheel Toe-Out: (A) - (B) = 1/8 - 1/4" (.3 to .6 cm)
TOE ADJUSTMENT
If toe alignment is incorrect, measure the distance
between vehicle center and each wheel. This will tell you
which tie rod needs adjusting.
2. Place a chalk mark on the center line of the front tires

approximately 10” (25.4 cm) from the floor or as
close to the hub/axle center line as possible.
NOTE
Be sure steering wheel is straight ahead before
determining which tie rod needs adjustment.
NOTE
It is important the height of both marks be equally CAUTION
positioned to get an accurate measurement. During tie rod adjustment, it is very important that the
following precautions be taken when tightening tie rod
3. Measure the distance between the marks and record end jam nuts.
the measurement. Call this measurement “A” q. If the rod end is positioned incorrectly it will not pivot,
4. Rotate the tires 180° by moving the vehicle forward. and may break.
Position chalk marks facing rearward, even with the
hub/axle center line. To adjust toe alignment:
• Hold tie rod end to keep it from rotating.
• Loosen jam nuts at both end of the tie rod.
MAINTENANCE
• Shorten or lengthen the tie rod until alignment is as

required to achieve the proper toe setting as specified
in “Wheel Toe Alignment”.
IMPORTANT
When tightening the tie rod end jam nuts, the rod ends
must be held parallel to prevent rod end damage and 2
premature wear. Damage may not be immediately
apparent if done incorrectly.
• After alignment is complete, torque jam nuts to

specification.
TORQUE
Tie Rod Jam Nut:
14 ft-lbs (19 Nm)
CAMBER AND CASTER

The camber and caster are non-adjustable.
MAINTENANCE
SUSPENSION
SUSPENSION INSPECTION SUSPENSION PIVOT POINT LUBRICATION
Compress and release the suspension. Damping should Grease all four front A-Arm pivot points q and all eight
be smooth throughout the range of travel. rear A-Arm pivot points w. See the maintenance chart
for service intervals or grease as needed.
• Check all suspension components and mounting
fasteners for wear or damage.
• Inspect each shock body for leakage.
SPRING PRE-LOAD ADJUSTMENT

The rear shock absorber springs are adjustable. Rotate
the adjuster cam q either direction to increase or
decrease spring tension. Always adjust both left and right
sides equally.
Vehicle loads effect suspension spring pre-load

requirements. Use Spanner Wrench to adjust pre-load as
necessary to avoid bottoming of the shocks.
Shock Spanner Wrench
2871095
NOTE
STABILIZER BAR PIVOT LUBRICATION Wheels removed for clarification only. Procedure can be
done with wheels installed on unit.
1. Grease stabilizer bar pivots q with a grease gun
until old grease is purged from the joint and new
grease appears. Inspect link isolators w for cracks.
MAINTENANCE
BRAKE SYSTEM
BRAKE FLUID INSPECTION BRAKE PAD INSPECTION
Always check the brake pedal travel and inspect the
1. Check the brake pads for wear, damage, or
brake fluid reservoir level before each operation. If the
looseness.
fluid level is low, add DOT 4 brake fluid only.
Brake fluid should be changed every two years. The fluid
2. Inspect the brake pad wear surface for excessive
wear.
2
should also be changed anytime the fluid becomes
contaminated, the fluid level is below the minimum level,
or if the type and brand of the fluid in the reservoir is
unknown.
The brake master cylinder reservoir q can be accessed
through the front left wheel well by opening the hood..
MEASUREMENT
Brake Pad
.030″ (0.762 mm)
3. If any one pad is less than the service limit then all
pads should be replaced.
2. Place the transmission in Park (P) and chock
wheels.
3. View the brake fluid level in the reservoir. The level
should be between the MAX and MIN level lines.
4. If the fluid level is lower than the MIN level line, add
brake fluid until it reaches the MAX level line.
5. Install the reservoir cap and apply the brake pedal
forcefully for a few seconds and check for fluid
leakage around the master cylinder fittings and the
brake caliper fittings.
BRAKE HOSE AND FITTING INSPECTION

Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
fittings and replace any worn or damaged parts.
MAINTENANCE
BRAKE DISC INSPECTION NOTE

1. Check the surface condition of the brake discs. This feature will not operate properly if the park brake
connector or switch (under the hood) malfunctions or
2. Measure the thickness of the front and rear brake becomes disconnected, or if the switch has moved.
discs. Refer to Electrical Chapter for diagnostics.
3. The disc (s) should be replaced if thickness is less
than the specified service limit 1. Pull back on the park brake lever.
2. After 2 to 3 clicks the “BRAKE” light should illuminate

on the indicator panel and the wheels of the vehicle
REF PART SERVICE LIMIT should not rotate when turning by hand. After 8 full
clicks of lever travel, the vehicle should not roll while
q Front Disc See the parked.
Specifications at the
beginning of the 3. If adjustment is required, return lever to the forward
Brakes Chapter position to release the brake. Adjust cable position in
the mounting bracket q on the transaxle as
w Rear Disc See the described in Steps 4-6.
beginning of the
Brakes Chapter
WARNING
Do not apply WD-40 or any petroleum product to brake
discs. These types of products are flammable and may
also reduce the friction between the brake pad and
caliper.
PARKING BRAKE ADJUSTMENT

When the park brake is set and the park brake indicator 4. Using two open-end wrenches, loosen outer jam nut
is illuminated, motor speed is limited. If the accelerator is w and inner jam nut e.
applied, this limiting feature prevents operation, which
protects the park brake pads from excessive wear. 5. Adjust cable outward to tighten brake.
MAINTENANCE
6. Tighten both jam nuts securely against bracket.
7. Inspect park brake adjustment from Steps 1-2.

8. Repeat Steps 4-6 until the proper adjustment is
obtained for the parking brake.
PARKING BRAKE PAD INSPECTION

Measure the thickness of the parking brake caliper front
pad q, rear pad w, and disc e. Replace if outside spec.
Refer to Brakes Ch. for service procedures.
MEASUREMENT
Parking Brake Pad Thickness - Front:
0.304 in (7.72 mm)
Service Limit: 0.24 in (6.1 mm)
MEASUREMENT
Parking Brake Pad Thickness - Rear:
0.360 in (9.14 mm)
Service Limit: 0.31 in (7.87 mm)
MEASUREMENT
Parking Brake Disc Thickness:
0.150-0.164 in (3.81-4.16 mm)
MAINTENANCE
NOTES
CHAPTER 3
ENGINE SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 3
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
ENGINE OIL FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9
ENGINE DETAIL - TORQUE VALUES - SEQUENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
ENGINE FASTENER TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11
SPARK PLUG / THROTTLE BODY / THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13
STATOR COVER / VALVE COVER / OIL SUMP COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14
CAMSHAFTS / CAM CARRIER / CAM CHAIN TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15
CYLINDER HEAD / CRANKCASE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
CRANKSHAFT / BALANCE SHAFT / CAM CHAIN GUIDES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17
ENGINE MOUNTING TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18
ENGINE / TRANSMISSION COUPLER BRACKET TORQUE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19
CYLINDER HEAD TORQUE SPECIFICATION / SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
STATOR COVER TORQUE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21
OIL SUMP COVER TORQUE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
LOWER CRANKCASE SEALANT PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.23
325 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25
COOLING SYSTEM FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.25
COOLING SYSTEM ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26
COOLING SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27
COOLING SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27
PRESSURE CAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.27
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28
COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.28
THERMOSTAT INSPECTION / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29
COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.30
WATER PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
TOP-END SERVICE (ENGINE IN CHASSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.33
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.36
ENGINE BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.39
325 ENGINE TO TRANSMISSION COUPLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.40
SETTING TDC (TOP-DEAD-CENTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.42
ENGINE DISASSEMBLY / INSPECTION - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43
VALVE COVER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43

VALVE COVER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.43
CAMSHAFT / CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.44
CAMSHAFT CARRIER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.45
CAMSHAFT SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47
EXHAUST CAMSHAFT DECOMPRESSION MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.47
CAMSHAFT OIL JET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.49
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.50
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.51
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.51
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52
COMBUSTION CHAMBER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.52
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.53
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.55
CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.55
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.55
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.56
PISTON / ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.56
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.57
ENGINE ASSEMBLY - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.58
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.58
PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59
CYLINDER INSTALLATION – PISTON INSTALLED ON CONNECTING ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.59
CYLINDER INSTALLATION - PISTON IN CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.60
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.62
CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.63
CAMSHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.64
CAMSHAFT TIMING - QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.67
VALVE CLEARANCE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.68
VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.69
325 INTAKE VALVE LASH - TAPPET SELECTION MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.70
325 EXHAUST VALVE LASH - TAPPET SELECTION MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.71
ENGINE DISASSEMBLY / INSPECTION - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.72
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.72
STATOR COVER / FLYWHEEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.72
STATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.73
STARTER ONE-WAY CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.73
OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.74
OIL PRESSURE REGULATOR (BYPASS) VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.75
STATOR COVER OIL SEAL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.75
BALANCE SHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.76
BALANCE SHAFT BEARING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.76
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.76
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.77
PTO AND MAG SIDE CRANKCASE BEARING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.78

OIL PICKUP ASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.79
CRANKCASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.79
ENGINE ASSEMBLY - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.80
CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.80
BALANCE SHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.81
STARTER ONE-WAY CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.82
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.82
OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.84
STATOR / STATOR COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.84
3
ENGINE / COOLING SYSTEM TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.86
ENGINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.86
COOLING SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.87
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.88
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.88
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.89
OIL PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.89
ENGINE OIL FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.90
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.91
ENGINE DETAIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.93
ENGINE FASTENER TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.93
TORQUE SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.95
CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.96
CYLINDER / OIL FILTER / OIL PUMP / BREATHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.97
CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / STATOR COVER - BLACK HEAD BOLTS . . . . . . . . . . . . . . . . .3.97
CAMS / CYL HEAD / FLYWHEEL / STATOR COVER - SILVER HEAD BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.99
SPARK PLUG / STARTER / THROTTLE BODY / VALVE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.100
PISTON / CRANKSHAFT / BALANCE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.101
ENGINE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.102
COOLING SYSTEM ASSEMBLY VIEW AND COOLANT FLOW DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.102
COOLING SYSTEM SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.103
COOLING SYSTEM PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.103
PRESSURE CAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.104
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.104
COOLANT DRAIN / RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.105
THERMOSTAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.106
COOLING SYSTEM BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.106
WATER PUMP COVER AND IMPELLER SERVICE (STATOR COVER REMAINS ON ENGINE) . . . . . . . . . . . 3.107
WATER PUMP MECHANICAL SEAL / OIL SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.108
ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.114
ACCESSIBLE ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.114
TOP-END SERVICE (ENGINE IN CHASSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.114
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.114
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.117
ENGINE BREAK-IN PERIOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.120
ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.120
ENGINE MOUNTING AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.121
SETTING TDC (TOP-DEAD-CENTER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.122

ENGINE DISASSEMBLY / INSPECTION - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.124
VALVE COVER REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.124
CAMSHAFT / CARRIER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.124
CAMSHAFT SPROCKET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.125
CAMSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.126
EXHAUST CAMSHAFT DECOMPRESSION MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.126
CAM CHAIN AND GUIDE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.127
CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.127
CYLINDER HEAD DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.128
CYLINDER HEAD IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.129
CRANKCASE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.129
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.130
CYLINDER HEAD WARP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.130
VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.130
COMBUSTION CHAMBER CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.131
VALVE SEAT RECONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.132
CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.134
CYLINDER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.134
PISTON REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.135
PISTON-TO-CYLINDER CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.135
PISTON / ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.136
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.136
HONING TO OVERSIZE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.137
CYLINDER HONE SELECTION / HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.138
CLEANING THE CYLINDER AFTER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.138
CAMSHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.138
CAMSHAFT TIMING - QUICK REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.141
ENGINE ASSEMBLY - TOP END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.142
PISTON RING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.142
PISTON / CONNECTING ROD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.143
CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.144
CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.144
VALVE SEALING TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.145
CYLINDER HEAD IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.146
CRANKCASE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.146
CYLINDER HEAD INSTALLATION - BLACK BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.147
CYLINDER HEAD INSTALLATION - SILVER BOLTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.148
VALVE CLEARANCE CHECK / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.149
VALVE LASH - TAPPET SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.152
EXHAUST VALVE LASH - TAPPET SELECTION MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.153
VALVE COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.154
ENGINE DISASSEMBLY / INSPECTION - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.155
CRANKCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.155
STATOR COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.155
STARTER ONE-WAY CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.155
STATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.157
OIL PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.158

OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.160
CRANKCASE BREATHER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.160
CRANKCASE SEPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.161
BALANCE SHAFT REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.162
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.163
CRANKSHAFT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.163
PTO SIDE CRANKCASE BEARING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.164
MAG SIDE CRANKCASE BEARING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.165
OIL PICKUP ASSEMBLY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.166 3
OIL PRESSURE REGULATOR (BYPASS) VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.166
CRANKCASE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.166
ENGINE ASSEMBLY - LOWER END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.167
CRANKCASE ASSEMBLY – PTO SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.167
BALANCE SHAFT INSTALLATION / TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.169
FINAL CRANKCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.169
STARTER ONE-WAY CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.171
FLYWHEEL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.171
STATOR / STATOR COVER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.173
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.174
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.174
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.175
3.1 325
GENERAL INFORMATION
ENGINE SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION
PU-50658 Clutch Center Distance Tool
PU-51220 Flywheel Holding Tool
PA-51423 Camshaft Alignment Tool
PA-51430 Camshaft Sprocket Holder

PA-51424 Crank-Balance Shaft Holder
PA-49316 Flywheel Puller
PU-50869 Water Pump Seal Installation Tool
PU-50569 Oil Pressure Gauge Adapter

PA-49317 Stator Cover Removal Handles
PV-1253 Valve Spring Compressor
PU-51038 Valve Spring Compressor Adapter
2872105–A Water Pump Seal Puller

Oil Pressure Gauge (0–10 psi / 6.9–69 kPa) Commercially Available
Bosch Automotive Service Solutions 1-800-345-2233

or https://polaris.service-solutions.com
ENGINE LUBRICATION SPECIFICATIONS 5. Upon assembly, torque the crankcase oil gallery plug
to specification. Apply Loctite 516 sealant to first two
FLUID CAPACITY thread under plug head.
Oil Capacity TORQUE
1.75 Quarts (1.65 L)
Oil Type Oil Gallery Plug:
Polaris PS-4 Synthetic Engine Oil 11 ft-lbs (15 Nm)Apply Loctite 516 sealant to first
Oil Pressure Minimum Specifications two thread under plug head
(using Polaris PS-4 at operating temperature)
1.0 PSI @ 1250 RPM (Minimum) Oil Pressure Minimum Specifications
5.0 PSI @ 7000 RPM (Minimum) (using Polaris PS-4 at operating temperature) 3
1.0 PSI @ 1250 RPM (Minimum)
OIL PRESSURE TEST
NOTE
The ProStar 32 engine features a low pressure
lubrication system. Use a low pressure gauge (1–10 psi
/ 6.9–69 kPa) to measure oil pressure.
1. Remove the seat and engine service panel.

2. Clean the area around the main oil gallery plug q,
located on the stator cover.
3. Remove the plug and install a commercially available

Oil Pressure Gauge which displays a minimum 1-10
psi (6.9–69 kPa) range in 1 psi (6.9 kPa) increments.
NOTE
The plug thread pitch is 1/8 NPTF.
4. Start engine and allow it to reach operating

temperature, monitoring gauge indication.
NOTE
Test results are based on the use of the recommended
engine oil (Polaris PS-4) at operating temperature, and
may vary considerably if any other oil is used or if
engine is not up to temperature.
ENGINE OIL FLOW CHART
ENGINE SPECIFICATIONS
CAMSHAFT / CYLINDER HEAD / CYLINDER
ITEM STANDARD SERVICE LIMIT
Cranking
Compres- Not provided - Engine uses decompression mechanism. Reference Leak Down Specification
sion
Cylinder Service Limit = 15%, engine at operating temperature, regulated 100 psi (690 kPa) at cylinder.
Leak Down
Cam Lobe Height - Intake 1.30 in. / 33.10 mm 1.28 in. / 32.6 mm 3
Cam Lobe Height - Exhaust 1.291 in. / 32.80 mm 1.27 in. / 32.3 mm
Camshaft Inspect by feel and fit. Replace

bearings and / or carrier assembly if
Camshaft Bearings damage or wear is found.
Exhaust camshaft large bearing is not
serviceable.
Cylinder - Surface Warp Limit (cylinder head
surface) .002 in. / 0.05 mm
3.07 +/– .0003 in.

Cylinder Bore 78.00 +/- 0.008 mm @ 33 mm down
Cylinder from top of cylinder
Cylinder Out of Round Limit .00078 in. / 0.020 mm

Cylinder Taper Limit .00078 in. / 0.020 mm
Cylinder to Piston Clearance .0003 - .002 in. / 0.008 - 0.062
Cylinder Surface Warp Limit .0039 in. / 0.1 mm
Head
Valve Lash (Cold) - Intake .005 ± .002″ (0.125 ± 0.05 mm)
Valve Lash (Cold) - Exhaust .014 ± .002″ (0.350 ± 0.05 mm)
Valve Stem Diameter - Intake .1958–.196 in. / 4.975-4.990 mm

Valve Stem Diameter - Exhaust .1950–.1956 / 4.955-4.970 mm
Valve
Valve Stem Oil Clearance - Intake .0003 - .0015 in. / 0.01 - 0.04 mm .0017 in. / 0.045 mm
Valve Stem Oil Clearance - Exhaust .0011 -.0023 in. / 0.03 - 0.06 mm .0025 in. / 0.065 mm
Valve Stem Overall Length - Intake 3.858 in. / 98.013 mm
Valve Stem Overall Length - Exhaust 3.426 in. / 87.0223 mm
Valve
Valve Guide Inner Diameter .1968 – .197 in. / 5.00 - 5.015 mm
Guide
Valve Seat - Contacting Width - Intake
.0393 in. / 1.00 mm
Valve Seat - Contacting Width - Exhaust
Valve Seat
17° ± 1.5°
Valve Seat Angles 45° ± 0.5°
70° ± 1.5°
PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT / OIL PUMP

O.D. - Measured 90° to pin (9.5 mm) up from
piston skirt 3.068–3.07 in. / 77.946 - 77.984 mm
Piston Piston Pin Bore I.D. .724–.740 in. / 18.4 - 18.8 mm .7100 in. / 18.036 mm
Piston Pin O.D. .708–.7086 in. / 17.995 - 18.00 mm .708 in. / 17.985 mm
Degree of fit Push fit (by hand) 68ºF / 20ºC
Top Ring .0074 - .0177 in. / 0.19–0.45 mm

Piston Installed
Rings Gap Second Ring .0074 - .0177 in.. /0.19–0.45 mm
Oil Control Rails .029 - 0.155 in. / 0.76–3.94 mm
Connecting Rod Small End I.D. .7086–.709 in. / 18.000 - 18.018 mm
Connecting rod small end radial clearance .0007-.0009 in. / 0.018 - 0.023 mm
Connecting
Rod Connecting rod big end side clearance .0059–.0177 in. / 0.15 - 0.45 mm
Connecting rod big end radial clearance .0009–.0014 in. / 0.023 - 0.038 mm
Crankshaft Runout Limit (PTO and MAG) .002 in / 0.05 mm

Runout Limit (PTO and MAG) .002 in / 0.05 mm
Balance Bearing Journal O.D. (Water Pump End) Inspect by feel and fit. Replace
Shaft bearings and / or carrier assembly if
Bearing Journal O.D. (Oil Pump End) damage or wear is found.
Rotor tip clearance .0059 in. / 0.150 mm
ENGINE DETAIL - TORQUE VALUES - SEQUENCES

ENGINE FASTENER TORQUE SPECIFICATIONS
325 ENGINE
DESCRIPTION TORQUE
Balance Shaft Nut 132 ft-lbs (180 Nm)
Balance Shaft Retainer 7 ft-lbs (10 Nm)
Fasteners
Camshaft Carrier Bolts 7 ft-lbs (10 Nm)
3
Camshaft Chain Guide 7 ft-lbs (10 Nm)
Fasteners
Camshaft Chain Guide 7 ft-lbs (10 Nm)
Screws
Camshaft Chain 6 ft-lbs (8 Nm)
Tensioner Screws
Camshaft Chain 6 ft-lbs (8 Nm)
Tensioner Spring Screws
Camshaft Oil Jet 6 ft-lbs (8 Nm)
Cam Chain Retainer 7 ft-lbs (10 Nm)
Screw
Crankcase Screws: 7 ft-lbs (10 Nm) (In
Sequence)
Crankshaft Position 9 ft-lbs (12 Nm)
Sensor (CPS) Fastener
Coolant Bleed Screw 6 ft-lbs (8 Nm)
Cylinder Head Bolts 9 ft-lbs (12 Nm)
Cylinder Head Nuts Cylinder Head Torque
Procedure:Step 1:
Torque the (4) M8 Nuts
in Sequence to 15 ft-lbs
(20 Nm)Step 2: Torque
the (4) M8 Nuts in
sequence 180° (1/2 turn)
Step 3: Torque the Outer
M6 Head Bolts to 9 ft-lbs
(12 ± 1 Nm)
Cylinder Head Studs 13 ft-lbs (17 Nm)
(Replacement required)
Decompression 27 ft-lbs (29 Nm)
Mechanism Screw
Exhaust Manifold Bolts 18 ft-lbs (24 Nm)
Flywheel Retaining Nut 133 ft-lbs (180 Nm)
Torque to specification,
back of 180 degrees,
retorque to
specification.
325 ENGINE 325 ENGINE

DESCRIPTION TORQUE DESCRIPTION TORQUE
Front Engine Mount 23 ft-lbs (31 Nm) Spark Plug 9 ft-lbs (12 Nm)
Isolators Do Not Apply Anti-seize
Front Engine Mount to 37 ft-lbs (50 Nm) Stator Bolts 9 ft-lbs (12 Nm)
Engine Bolts
Stator Cover Bolts 9 ft-lbs (12 Nm)
Intake & Exhaust 14 ft-lbs (19 Nm) Apply Loctite® 242™
Camshaft Sprocket Bolt
Starter Motor Bolts 7 ft-lbs (10 Nm)
Oil Filter Cover 88 in. lbs. (10 Nm)
Stator Wire Bracket Bolts 6 ft-lbs (9 Nm)
Oil Gallery Plug 11 ft-lbs (15 Nm) Apply Loctite® 242™
Apply Loctite 516
sealant to first two Thermostat Cover Bolt 7.3 ft–lbs (10 Nm)
thread under plug head
Valve Cover Bolts 7 ft-lbs (10 Nm)
Oil Pan Drain Plug 12 ft-lb (17 Nm)
Valve Cover Breather 3 ft-lbs (4 Nm)
Oil Pickup Screws 5 ft-lbs (7 Nm) Plate Screws
Oil Pump Cover Bolts 7 ft-lbs (10 Nm) Water Pump Cover Screw 7 ft-lbs (10 Nm)
One Way Clutch 9 ft-lbs (12 Nm) NOTE: Refer to the diagrams and procedures within
Retaining Bolts Apply Loctite® 272™ the chapter for fastener identification.
Piston Oil Jet 3 ft-lbs (4 Nm)

Rear Engine Mount to 44 ft-lbs (59 Nm)
Engine Screws (In sequence)
Rear Engine Mount to 23 ft-lbs (31 Nm)
Frame Fasteners
SPARK PLUG / THROTTLE BODY /

THERMOSTAT
STATOR COVER / VALVE COVER / OIL

SUMP COVER
Apply a drop of Loctite 641 (Yellow) to the crankshaft

taper before flywheel assembly. Loctite 603 (Green)
can be used if 641 is not available.
CAMSHAFTS / CAM CARRIER / CAM CHAIN TENSIONER
CYLINDER HEAD / CRANKCASE
CRANKSHAFT / BALANCE SHAFT / CAM CHAIN GUIDES
ENGINE MOUNTING TORQUE SPECIFICATIONS
ENGINE / TRANSMISSION COUPLER BRACKET TORQUE SEQUENCE
CYLINDER HEAD TORQUE SPECIFICATION / SEQUENCE
STATOR COVER TORQUE SEQUENCE
NOTE
When reinstalling stator cover, do not force stator cover to fit. Align the oil pump shaft with the balance shaft drive
tang. Turn the engine by rotating the drive clutch or similar method to turn balance shaft.
OIL SUMP COVER TORQUE SEQUENCE
NOTE
Install new sump cover gasket whenever the sump is removed from the crankcase.
LOWER CRANKCASE SEALANT PATTERN
325 EXHAUST SYSTEM
325 EXHAUST SYSTEM

REF. DESCRIPTION FASTENER TORQUE / NOTE
1 Exhaust Pipe
2 Silencer Assembly Shield Screws: 8 ft-lbs (11 Nm)
3 Head Pipe
4 Bushings
5 Exhaust Seals
6 Sealing Gaskets
7 Lower Exhaust Mount
8 Rubber Washer
9 Vibration Damper
10 Grommets
11 Isolator Mount
12 Exhaust Springs
13 Carriage Bolts
14 Screws 8 ft-lbs (11 Nm)
15 Exhaust Manifold Bolts 18 ft-lbs (24 Nm)
16 Hex Nuts 18 ft-lbs (24 Nm)
17 Washers
18 Lock Washers
ENGINE COOLING SYSTEM

COOLING SYSTEM FLOW
COOLING SYSTEM ASSEMBLY VIEW
REF. DESCRIPTION NOTES

q Hose Clamp
w Coolant Line Clamp
e Coolant Line Clamp Screw
r Pressure Cap
t Recovery Tank
y Recovery Tank Tube
u Radiator Lower Mount Bushing
i Radiator
o Clamp Springband
a Coolant Tube In
s Coolant Tube Out
COOLING SYSTEM SPECIFICATIONS COOLING SYSTEM PRESSURE TEST

1. Remove the hood from the front cab.
COOLANT
CONDITION TEMPERATURE °F (° WARNING
C)
Never remove pressure cap when engine is warm or
Room Temperature 68° F (20° C) hot. The cooling system is under pressure and serious
burns may result. Allow the engine to cool before
Thermostat Open 180° F (82° C) servicing.
Thermostat Full Open Lift 203° F (95° C)
2. Remove pressure cap and pressure test the cooling
Fan ON 204° F (96° C) system using a commercially available pressure 3
tester.
Fan OFF 194° F (90° C)
Engine Temperature
Overheat Indicator 231° F (111° C)*
Engine Protection Ignition
Misfire 235° F (113° C)*
Engine Protection Shutdown 242° F (117° C)*

* = Actual value determined by vehicle speed (stopped
or moving). Listed value is conservative setting.
Item Specification
Cooling System Capacity Liquid Cooled / 86 oz.
(2.5 l) 3. The system must maintain 10 psi for five minutes or
longer. If pressure loss is evident within five minutes,
Coolant Recovery Bottle 8 oz. (237 ml) check the filler neck, radiator, hoses, clamps and
Capacity water pump weep hole for leakage.
Pressure Cap Relief 13 PSI
PRESSURE CAP TEST
1. Open the hood (see “WARNING” under “Cooling
Polaris Premium Antifreeze:
System Pressure Test”).
2880514 - Quart
2880513 - Gallon 2. Remove pressure cap q and test using a pressure
cap tester (commercially available).
Recommended Coolant
Use only high quality antifreeze/coolant mixed with
distilled water in a 50/50 or 60/40 ratio, depending on
freeze protection required in your area.
CAUTION: Using tap water in the cooling system will
lead to a buildup of deposits which may restrict coolant
flow and reduce heat dissipation, resulting in possible
engine damage. Polaris Premium 50/50 Antifreeze/
Coolant is recommended for use in all cooling systems
and comes pre-mixed, ready to use.
3. The pressure cap relief pressure is 13 psi. Replace

cap if it does not meet this specification.
RADIATOR COOLANT DRAIN / RADIATOR REMOVAL

1. Check radiator air passages for restrictions or Coolant Drain
damage.
1. Open the hood.
WARNING
Never drain the coolant when the engine and radiator
are warm or hot. Hot coolant can cause severe burns.
Allow engine and radiator to cool.
2. Slowly remove the pressure cap to relieve any

cooling system pressure.
3. Place a suitable drain pan underneath the drain
valve on the front left side of the vehicle.
4. Drain the coolant from the radiator by opening the
drain valve q in the lower left corner of the radiator.
Properly dispose of the coolant.
pressure water.
CAUTION
damage the radiator fins and impair the radiators
effectiveness. Use of a high-pressure washer is not
recommended.
5. Allow coolant to completely drain.

6. Place a suitable drain pan underneath the lower
engine hose w on the right rear side of the vehicle.
7. Remove the hose and completely drain the engine.

Radiator Removal
8. Remove the upper engine outlet hose and recovery
hose from the top of the radiator.
9. Remove the two upper radiator retaining bolts e. THERMOSTAT INSPECTION /

REPLACEMENT
1. Drain the cooling system (Refer to “Coolant Drain /
Radiator Removal”, page ).
2. Remove the thermostat cover bolts q.
10. Disconnect the fan motor and remove the radiator

from the vehicle. Take care not to damage the
cooling fins.
11. Reverse procedure for installation.
3. Remove the thermostat w and O-ring seal e from

the water pump cover.
4. Install the new thermostat and O-ring seal.
5. Install the thermostat cover and cover bolts. Torque
the cover bolts to specification.
TORQUE
Thermostat Cover Bolt:
7.3 ft–lbs (10 Nm)
6. Refill and bleed the cooling system. (Refer to

“Cooling System Bleeding Procedure”).
COOLING SYSTEM BLEEDING TORQUE

PROCEDURE Coolant Bleed Screw:
6 ft-lbs (8 Nm)
CAUTION
Procedure requires running engine at mid-throttle.
Never run the engine in an enclosed space. Perform
procedure outside in a well-ventilated area. Place
vehicle in PARK. Do not engage parking brake, if
equipped, to prevent RPM limiter from activating.
Allow engine and exhaust components to cool
completely prior to servicing.
1. Turn the engine off and place the vehicle in PARK.

2. Open the front box cover and remove the radiator cap
access panel (1).
6. Fill coolant to the top of the filler neck.

7. Repeat steps 5 and 6.
8. Install the radiator pressure cap.
9. Start the engine and run at 3000 to 4000 RPM until
the radiator cooling fan cycles on and off.
10. Stop the engine and allow the cooling system to
completely cool.
11. Repeat steps 3 through 10.
12. Fill coolant recovery bottle to the MAX line.
3. Remove radiator pressure cap (2). 13. Test drive to confirm proper cooling system operation.
CAUTION
Never remove pressure cap when engine is warm or
hot. The cooling system is under pressure and serious
burns may result. Allow the engine to cool before
servicing.
4. Fill system with approved coolant to the top of the

filler neck.
5. Open the bleed screw (3) located to the left and
below the intake track on the cylinder head to allow all
air to escape, then close the screw.
WATER PUMP SERVICE

Removal
1. Remove four screws q and Water Pump Cover w.
NOTE
Mechanical seal shown disassembled using special
2. Remove Water Pump Impeller e. tool. New seal is one-piece.
4. An oil seal y is located behind the mechanical seal

bore. This seal should be replaced when replacing
the mechanical seal.
NOTE
Water pump impeller has left hand threads.
3. Remove Water Pump Seal r using special tool 5. Use a small pick to puncture the seal and pull it out of
2872105–A. The water pump seal shell t will remain the bore.
in the engine and will need to be removed. Carefully 6. Install a new oil seal with the seal lips towards the
pry around the outer edge of the seal body with a pick balance shaft.
or small flat-blade screw driver.. Do not damage the 7. Press seal into bore until it is flush with the case
mating surface. Continue prying around the outer surface u.
circumference until the seal body is removed from the
bore.
Installation
1. Using the seal driver included with special tool PU-
50869, install new Water Pump Seal r & t into the
engine case.
IMPORTANT
The mechanical seal driver included with special tool
PU-50869 is designed to compress the seal to a
specific height required for proper operation. Do not use
any other type of seal driver to install mechanical seal.
2. Install Water Pump Impeller e to hand tightness.
NOTE
The Impeller has left hand threads.
3. Install Water Pump Cover w and four screws q.

Torque screws to specification.
TORQUE
Water Pump Cover Screw:
7 ft-lbs (10 Nm)
ENGINE SERVICE
ACCESSIBLE ENGINE COMPONENTS ENGINE REMOVAL
The following components can be serviced or removed
with the engine installed: NOTE
• Valve Cover Some engine repair procedures can be performed
• Camshafts without removing the engine assembly from the vehicle.
• Camshaft Sprockets Refer to “Accessible Engine Components” for further
• Cylinder Head and Gaskets information.
• Cylinder and Gaskets The use of an overhead or portable engine hoist is the
only recommended method for removing and installing
•
•
Piston and Rings
Thermostat the engine. 3
• Water Pump Have an assistant help guide the engine in and out of
• Starter Motor the vehicle while using an engine hoist to prevent
• Crankshaft Seal (PTO) personal injury or damage to vehicle components.

with the engine installed but requires removal of the CAUTION
engine to transmission adapter fasteners. Correct Drive Clutch Puller P/N PA-48595
NOTE
Refer to the Engine to Transmission Adapter Service
Procedure.
• Flywheel
• Starter Idler Gear / Shaft Assembly
• Stator (Alternator)
• Oil Pump
• Oil Pressure Regulator
• Counterbalance Shaft and Bearings
The following components require engine removal for
service:
• Crankshaft and Bearings
• Camshaft Timing Chain and Guides
• Crankcase
• Oil Pump Pickup Assembly
WARNING
Always wear safety glasses and proper shop clothing
TOP-END SERVICE (ENGINE IN CHASSIS) when performing the procedures in this Service
ALL of the top-end engine components can be serviced Manual.
while the engine is mounted in the chassis. Failing to do so may lead to possible injury.
1. If vehicle was recently operated, allow it to cool down

before attempting to perform any work.
2. Thoroughly clean the engine and chassis.
3. Drain the engine oil and engine coolant prior to 11. Disconnect the ETC (item 8) , T-MAP sensor (item
engine removal (see Chapter 2). 7), harness leads from the throttle body.
4. Disconnect the (-) negative battery cable from the 12. Remove the throttle body assembly from the engine.
battery. Insert a clean shop towel into the engine intake to
prevent foreign material from entering the engine.
5. Remove the seat.
Secure the throttle body assembly/cable to the
6. Remove the rear cargo box as an assembly (see chassis.
Body / Frame Chapter). Remove the box tilt shock 13. Disconnect the fuel injector harness lead from the
lower mount pin and remove the box tilt shock from
fuel injector.
the frame.
14. Place a shop to beneath the fuel line quick connector
7. Loosen the clamps securing the intake duct to air to catch any fuel. Disconnect the fuel line from the
box rubber boot to the throttle body. Disengage the fuel rail by pressing in on the quick connector tabs.
assembly from the boots and place off to the left
side. 15. Move fuel line to the left-hand side of the engine
compartment. Make note of line routing for
NOTE installation.
Be sure dirt and debris do not enter the engine, air box
16. Remove the spark plug wire from the engine.
or throttle body. Use clean shop towels to plug engine
and air box intake holes. 17. Remove (+) positive cable (Item 1) from the starter
motor.
8. Remove the outer clutch cover, driven clutch, drive
belt, drive clutch and inner clutch cover. (see
Chapter 6).
NOTE
Be sure to use the correct Drive Clutch Puller (PA-
48595) to prevent damage to crankshaft.
9. Disconnect the stator wire connector and cut the tie

strap securing the wiring to the front engine mount
bracket. Replace tie strap for engine installation.
10. Disconnect the CPS sensor from the wiring harness.
18. Remove (-) negative cable (Item 2) from the starter

mounting nut. If desired, remove the remaining
starter motor bolt and remove the starter motor from
the engine.
19. Disconnect the upper engine coolant hose, bypass
hose and ECT harness connector.
20. Remove the bolts securing the muffler to the frame. 27. With the help of an assistant and the engine hoist,
Remove the bolts securing the exhaust head pipe to raise the engine vertically out of the vehicle frame.
the engine. Maneuver the exhaust assembly out of
the mounting grommet and remove the exhaust NOTE
assembly as one. Have an assistant help guide the engine in and out of
21. Place a support between the main frame and the vehicle while using an engine hoist to prevent
transmission case. Do not pinch any lines. personal injury or damage to the vehicle components.
22. Use an overhead or portable engine hoist and
suitable engine straps to secure the engine in its
current position.
23. Remove the bolts and nuts (Item 3) securing the
3
engine to the front motor mount bracket.
24. Place a block of wood under the transmission.
Remove the lock nuts and washers from the engine
to transmission coupler mounting bolts.
25. Remove the engine to transmission coupler through

bolts and discard.
26. Using a 12 mm hex drive, turn the take-up nuts (3)
clockwise to release the transmission ears from the
mount.
ENGINE INSTALLATION 4. Install the front engine mount bolts and torque to
Use the following procedure to reinstall the engine specification.
assembly.
TORQUE
1. Install the engine to transmission coupler (1) onto Front Engine Mount Bolts:
the engine. Torque new bolts (2) in sequence (see
30 ft-lbs (41 Nm)
image below) to specification.
5. Insert NEW engine to transmission coupler bolts (3)
half way into the engine to transmission coupler.
TORQUE
Engine to Transmission Coupler Engine Mounting
Bolts:
44 ft-lbs (59 Nm) (In sequence)
2. Clean the take-up nut (4) threads and install into the
engine to transmission coupler (1) by hand.
3. Attach suitable lifting straps to the engine and use an
overhead or portable engine hoist to lower the
engine into the vehicle frame. Place spacer blocks
under transmission and engine to assist with
alignment of the engine to transmission adapter
fasteners.
NOTE
Have an assistant help guide the engine in and out of
the vehicle while using an engine hoist to prevent
personal injury or damage to vehicle components.
6. Install the Clutch Center Distance Tool (PU-50658 or HOLE YEAR VEHICLE DESCRIPTION
PU-50658-A) onto the crankshaft and transmission 2015-18 RZR 900
input shaft. The pictures below show a properly 2016-18 RZR 1000
installed tool (PU-50658).
2016–18 ACE 900
5 2015-18 RANGER Diesel
i.e. 2015 RZR 900 uses the holes marked with a

4
7. Torque the upper, then lower engine to transmission
adapter take up nuts (4) counterclockwise to
specification. Repeat the Step 7 process.
TORQUE
Engine to Transmission Coupler Take Up Nut:
60 in-lbs (6.7 Nm)
8. Fully insert the NEW engine to transmission coupler

bolts (3). Install NEW washers (5) and torque NEW
nuts (6) to specification.
TORQUE
NOTE
Engine to Transmission Coupler Nuts:
Images for Reference only. The tool shown should only
be used to check center to center distance. 88 ft-lbs (119 Nm)
The location the tool rests on the shafts may vary.
9. Remove the lifting straps and overhead or portable
engine hoist and remove the spacer blocks
previously installed under the transmission and
PU-50658–A engine.
HOLE YEAR VEHICLE DESCRIPTION 10. Install the exhaust manifold and torque the fasteners
1 2012 RZR 570 to specification.
2011-14 RZR 900
2 2014-15 RZR XP 1000
TORQUE
2013 RANGER 900 Exhaust Manifold Bolts:
2014-16 ACE 18 ft-lbs (24 Nm)
2015-18 ACE 570
11. Install the exhaust pipe.
2015-16 RGR ETX
3 12. Install the coolant hoses onto the engine.
2013–18 RZR 570
2014–18 RANGER 500/570 13. Install the throttle body and air box. Tighten the hose
2015-18 RANGER 570 Full-Size clamps that secure the throttle body to the intake
4 2014-18 RANGER 900/1000 duct, intake boot and air box.
14. Connect the positive battery cable to the starter 31. Check the engine oil level. .
motor and negative cable to the starter mount.
32. Verify proper operation.
TORQUE
Starter Motor Bolts:
7 ft-lbs (10 Nm)
15. Connect the TMAP sensor (7) and ETC (8). Verify
harness routing is correct.
16. Connect the fuel injector harness lead to the fuel

injector.
17. Connect the fuel line to the fuel rail.
18. Connect the ignition coil harness connector and
install the spark plug wire.
19. Connect the CPS connector to the wiring harness.
20. Connect the stator wire connector and install a new
tie strap to secure the wiring to the mount bracket.
21. Install the inner clutch cover as outlined in chapter 6.
22. Install the drive clutch, driven clutch, belt and outer
clutch cover as outlined in Chapter 6. Be sure all
hose and wire routing is correct. Torque all fasteners
to specification as outlined in Chapter 6.
23. Install the cargo box assembly as outlined in the
Body / Frame Chapter.
24. Remove the pressure cap and fill the cooling system
through the filler neck with properly mixed anti-freeze
/ coolant.
25. If the engine oil was completely drained, add
approximately 1.75 quarts (1.65 L) of Polaris PS-4
Synthetic Engine Oil into the crankcase.
26. Install a new oil filter.
27. Connect the (-) negative battery cable to the battery.
28. Install the seat.
29. Follow the cooling system bleeding procedure as
outlined in this chapter.
30. Start engine and check for any oil or coolant leaks.
ENGINE BREAK-IN PERIOD ENGINE LUBRICATION SPECIFICATIONS

The break-in period consists of the first 25 hours of
operation, or the time it takes to use 15 gallons (57 liters) FLUID CAPACITY
of fuel. Careful treatment of a new engine and drive Oil Capacity
components will result in more efficient performance and 1.75 Quarts (1.65 L)
longer life for these components. Oil Type
Polaris PS-4 Synthetic Engine Oil
CAUTION Oil Pressure Minimum Specifications
Use only Polaris PS-4 Synthetic Engine Oil. (using Polaris PS-4 at operating temperature)
Never substitute or mix oil brands. 5.0 PSI @ 7000 RPM (Minimum) 3
Serious engine damage and voiding of warranty can
result.
Do not operate at full throttle or high speeds for

extended periods during the first three hours of use.
Excessive heat can build up and cause damage to
close fitted engine parts.
1. Fill fuel tank with unleaded fuel which has a minimum

pump octane number of 87 = (R+ M)/2.
2. Refer to Chapter 2, “Engine Oil Level”, page 2.20.
Check oil level indicated on the dipstick. Add oil if
necessary.
3. Drive slowly at first to gradually bring engine up to
operating temperature.
4. Vary throttle positions. Do not operate at sustained
idle or sustained high speed.
5. Perform regular checks on fluid levels, controls and
all important bolt torques.
6. Change oil and oil filter after break-in period at 25
hours.
325 ENGINE TO TRANSMISSION COUPLER 4. Remove the transmission mount through bolts e and
SERVICE discard.
Disassembly Procedure 5. Using a 12 mm hex drive, turn the take-up nuts r
IMPORTANT mount.
The engine / transmission bracket mounting bolts,
washers and flange nuts must always be discarded
when the nuts are either loosened or removed. Failure
to use new mounting hardware during reassembly may
cause damage to the engine crankcase, mounting
bracket, or transmission mounting ears.
1. Remove the outer clutch cover, drive belt, drive

clutch, driven clutch, inner clutch cover and clutch
outlet duct (see Chapter 6).
2. Place a spacer or support between the vehicle frame
and engine to hold the engine in position.
NOTE
Image for reference only.

Remove the lock nuts y and washers t from the
engine to transmission adapter mounting bolts (3)
and discard.
Assembly Procedure NOTE

1. Clean the take-up nut r threads and install into the Images for Reference only. The tool shown should only
engine to transmission coupler q by hand. be used to check center to center distance.
2. Insert NEW engine to transmission coupler bolts e The location the tool rests on the shafts may vary.
PU-50658–A
HOLE YEAR VEHICLE DESCRIPTION
1 2012 RZR 570
2011-14 RZR 900 3
2 2014-15 RZR XP 1000
2013 RANGER 900
2014-16 ACE
2015-18 ACE 570
2015-16 RGR ETX
3
2013–18 RZR 570
2014–18 RANGER 500/570
2015-18 RANGER 570 Full-Size
2014-18 RANGER 900/1000
3. Install the Clutch Center Distance Tool onto the 2015-18 RZR 900
4
crankshaft and transmission input shaft. The pictures 2016-18 RZR 1000
below show a properly installed tool. 2016–18 ACE 900
i.e. 2015 RZR 900 uses the holes marked with a 4
4. Turn the upper and then lower take up nuts (4)

counterclockwise (4) to no more than the specified
torque. Repeat the step 4 process.
TORQUE
60 in-lbs (6.7 Nm)
IMPORTANT
Do not over-torque the take up nuts. Torque nuts using
the sequence described in step 4. If too much torque is
applied to the take up nuts, the transmission mounting
Clutch Center Distance Tool ears may break.
PU-50658 or PU-50658-A
5. Fully insert the NEW engine to transmission coupler 2. View the timing marks on the camshaft sprockets to
bolts e. Install NEW washers t and torque NEW ensure the engine is at TDC on the compression
nuts y to specification. stroke
TORQUE NOTE
Engine to Transmission Coupler Nuts: Intake cam sprocket should have “I” marks aligned with
88 ft-lbs (119 Nm) gasket surface and the exhaust cam sprocket should
have “E” marks aligned with gasket surface.
6. Reinstall PVT Inner Cover, Driven Clutch, Drive

Clutch and PVT Outer Cover.
SETTING TDC (TOP-DEAD-CENTER)

To ensure the piston is at TDC. Remove the outer clutch
cover to access the drive clutch to aid in engine rotation
(manually turn the drive clutch counter clockwise).
1. With the CPS sensor removed, rotate the engine
until the “<” marked on the flywheel q is aligned with
the CPS mounting hole. This will set TDC, but not
necessarily TDC of the compression stroke.
3. See Camshaft Timing - Quick Reference, page 3.67

for additional information.
ENGINE DISASSEMBLY / INSPECTION - TOP END

VALVE COVER REMOVAL 6. Replace isolators e and valve cover seal r if oil
leaks are evident.
NOTE
NOTE
The valve cover, camshafts, cylinder head, cylinder and
piston can be serviced with the engine installed in the Carefully pass the spark plug hole section q of the
chassis. valve cover seal under the cam carrier bridge w to
remove or install the seal.
1. Disconnect the spark plug wire from the spark plug
q by firmly grasping the wire boot and twist slightly 3
while lifting up.
2. Remove dirt and debris from valve cover area.
3. Remove the spark plug q. Stuff spark plug hole with
a shop towel to prevent debris from entering the
combustion chamber (if further engine disassembly
is required).
4. Remove three valve cover shoulder bolts w and
isolators e using a T40 driver.
5. Carefully lift valve cover from the engine and remove
it.
IMPORTANT
Discard valve cover Isolators upon removal. New
Isolators are required once removed.
Inspect the valve cover seal and replace if damaged or

signs of leaking are present.
VALVE COVER INSPECTION

Inspect the breather plate q for damage. Remove the
screws w and clean passages in cover.
After cleaning valve cover, reinstall breather plate and

torque screws to specification.
TORQUE
Valve Cover Breather Plate Screws:
3 ft-lbs (4 Nm)
CAMSHAFT / CARRIER REMOVAL 5. Remove the intake camshaft gear from the intake
camshaft.
NOTE
6. Attach a hook or other tool to the camshaft chain to
The camshafts can be removed with the engine prevent it from dropping down into the engine.
installed in the chassis.
7. Remove the camshaft carrier fasteners.
Camshaft Carrier Removal
1. Remove the valve cover assembly (Refer to “Valve
Cover Removal”, page 3.43).
2. Rotate the crankshaft so the piston is at Top Dead
Center (TDC) on the compression stroke and
camshaft lobes are facing out from center.
NOTE
To verify TDC, see: SETTING TDC (TOP-DEAD-
CENTER), page 3.42.
3. Remove the cam chain tensioner q from the

cylinder. Replace the gasket w upon reassembly.
8. Remove the camshaft carrier assembly from the

cylinder head.
4. Install PA-51430 Camshaft Sprocket Tool e on the

intake camshaft sprocket and remove the intake
camshaft sprocket bolt.
CAMSHAFT CARRIER DISASSEMBLY
q Camshaft Sprocket Bolt o Bearing Support

w Washer a Exhaust Camshaft (Sprocket, snap ring, and bearing
not serviceable.)
e Intake Camshaft Sprocket s Snap Ring

r Snap Ring d Decompression Spring
t Bearing f Decompression Shaft
y Intake Camshaft g Decompression Disc
u Bearing Support h Screw
i Bearing
Camshaft Carrier Disassembly 6. Support the camshaft carrier assembly in a suitable

shop press at the points shown. Press both the intake
1. Remove the camshaft carrier assembly. See:
and exhaust camshafts simultaneously to force the
Camshaft / Carrier Removal , page 3.44.
bearings i from the PTO side bearing support.
2. Remove the intake camshaft sprocket bolt q, washer
w and sprocket e.
3. Remove the intake camshaft bearing retaining snap
ring r.
4. Remove the decompression device retaining screw
h, washer g, shaft f and spring d from the
exhaust camshaft.
5. Rotate the exhaust camshaft gear opening to remove
the bearing retaining snap ring s that is captured
between the pressed on exhaust camshaft gear and
bearing.
NOTE
The exhaust camshaft gear is pressed onto the exhaust
camshaft during manufacturing and cannot be removed
from the exhaust camshaft.
7. Support the camshaft carrier assembly at the points

shown and press the camshafts individually from the
MAG side bearing support.
8. Reverse disassembly procedure for reassembly.
CAMSHAFT SPROCKET INSPECTION 2. Measure the height of each cam lobe from the base
circle to highest point on the lobe using a
NOTE micrometer. Compare to specification.
Camshaft sprocket removal is not necessary unless the
replacement of the sprockets is required.
Inspect cam sprocket teeth for wear or damage. Replace

timing chain and sprockets as a set if worn or damaged.
NOTE
Replace camshafts if damaged or if any part is worn
past the service limit.
MEASUREMENT
NOTE Camshaft Lobe Height:
Intake: 1.30" (33.10 mm)
Replace intake camshaft sprocket bolt if loosened or
Exhaust: 1.291" (32.80 mm)
removed.
TORQUE EXHAUST CAMSHAFT DECOMPRESSION

Intake & Exhaust Camshaft Sprocket Bolt: MECHANISM
14 ft-lbs (19 Nm)
NOTE
Removal of the decompression mechanism is not
CAMSHAFT INSPECTION necessary unless replacement is required.
Inspect all cam lobes as described below and compare
to specifications. Replace camshafts if worn beyond The decompression mechanism consists of screw q,
service limit or if any surface is pitted or damaged. domed washer w, flyweight e, and spring r.
1. Visually inspect each cam lobe for wear or damage.
During engine start up, the spring holds the flyweight in

the active position.
1. When servicing the decompression system, note the

orientation of the domed washer. The dome faces
inwards.
A cam is located on the end of the flyweight. In the active
position, the cam pushes against the tappet to open the 2. Replace the decompression assembly if any
exhaust valve and bleed cylinder pressure. excessive wear or binding is evident.
3. During assembly, install the spring so A fits around
the flyweight, and the spring tail B engages the
camshaft flat B.
As the engine starts, the camshaft rotational speed

increases dramatically. Centrifugal force causes the
flyweight to override the spring pressure and swing out
away from the camshaft. 4. Install the domed washer with the dome facing
inwards. Install screw and torque to specification.
TORQUE
Decompression Mechanism Screw:
27 ft-lbs (29 Nm)
5. Be sure the decompression mechanism functions

smoothly and easily returns under spring pressure to
the resting position against gravity.
The cam on the flyweight rotates into recess on the

camshaft and no longer makes contact with the tappet.
CAMSHAFT OIL JET 4. Tap cylinder head lightly with a soft faced hammer
An oil jet q is located on the MAG side camshaft carrier. until loose. Tap only in reinforced areas or on thick
The oil jet sprays oil at the intake camshaft creating an oil parts of the cylinder head casting.
mist which lubricates the cam train components. 5. Remove the cylinder head e and head gasket r.
During engine inspection, the jet should be removed and

cleaned to remove any deposits or foreign material.
When reinstalling jet, torque to specification. CYLINDER HEAD DISASSEMBLY
TORQUE CAUTION
Camshaft Oil Jet: Wear eye protection during cylinder head disassembly
6 ft-lbs (8 Nm) and reassembly or when working with the valve springs.
NOTE
CYLINDER HEAD REMOVAL
Keep mated parts together and in order with respect to
NOTE their location in the cylinder head for assembly
purposes. It is important to install cylinder head
The cylinder head can be serviced with the engine components back in the same location. Mark each
installed in the chassis. component or place them in an organized rack as you
Do not rotate head assembly up side-down until the remove them.
valve tappets have been removed.
1. Remove the valve tappet q from the cylinder head.
NOTE
The cylinder head studs must be replaced any time the
cylinder head nuts are loosened.
TORQUE
Cylinder Head Studs:
13 ft-lbs (17 Nm) (Replacement required)
1. Loosen the cylinder head nuts w in sequence (Refer

to Cylinder Head / Crankcase Torque Specs /
Sequence) evenly 1/8 turn (60 degrees) at a time
until all are loose.
2. Remove and discard the nuts that retain the cylinder
head and the cylinder.
3. Remove the q cylinder head bolts.
2. Compress the valve spring using valve spring 5. Remove the valve retainer w, valve spring r, valve
compressor (PV-1253) and adapter (PU-51038). stem seal t and valve spring seat y. Discard the
valve seal.
NOTE
Replace valve seals whenever cylinder head is
disassembled. Hardened, cracked or worn seals will
cause excessive oil consumption.
6. Lift up the cylinder head and push the valve u out,

keeping it in order for reassembly in the same valve
guide.
7. Repeat the previous steps to remove the remaining
valves.
8. Clean the combustion chamber and head gasket
surface.
9. Measure the free length of each valve spring with a
vernier caliper and compare to specification.
3. Push down on the spring and remove the split

keepers e.
MEASUREMENT
Valve Spring Free Length:
Standard: 1.667" (42.33 mm)
CYLINDER HEAD INSPECTION

Thoroughly clean cylinder head surface to remove all
traces of gasket material and carbon.
CAUTION
Use care not to damage gasket sealing surface. All
gasket surfaces must be clean, dry and free of any oil
4. Slowly release valve spring pressure and remove the or grease upon assembly. Clean sealing surfaces with
compressor adapter. rubbing alcohol or electrical contact cleaner. Do not
touch sealing surfaces of the new head gasket.
CYLINDER HEAD WARP INSPECTION 4. Check the end of the valve stem for flaring, pitting,
1. Lay a straight edge q across the surface of the wear or damage.
cylinder head at several different points and measure
warp by inserting a feeler gauge between the straight
edge and the cylinder head surface. If warp exceeds
the service limit, replace the cylinder head.
5. Inspect split keeper groove for wear or flaring in the

keeper seat area.
NOTE
The valves can be re-faced or end ground, if necessary.
They must be replaced if extensively worn, burnt, bent
or damaged.
MEASUREMENT 6. Measure diameter of valve stem with a micrometer in

three places, then rotate 90° and measure again
Cylinder Head Warp Limit: (take six measurements total). Compare to
.0039" (0.1 mm) specifications.
VALVE INSPECTION
1. Remove all carbon from valves with a soft wire wheel
or brush.
2. Check valve face for excessive runout, pitting, and
burnt spots.
3. To check for bent valve stems, mount valve in “V”
blocks and measure with a dial indicator.
MEASUREMENT
Intake Valve Stem Diameter:
.1958–.196 in. / 4.975-4.990 mm
Exhaust Valve Stem Diameter:
.1950–.1956 / 4.955-4.970 mm
7. Measure valve guide inside diameter at the top COMBUSTION CHAMBER CLEANING
middle and end of the guide using a small hole
gauge and a micrometer. Measure in two directions. CAUTION
Wear eye protection during combustion chamber
cleaning.
1. Clean all accumulated carbon deposits from

combustion chambers and valve seat area q.
MEASUREMENT
Valve Guide I.D.:
.1968 – .197 in. / 5.00 - 5.015 mm
8. Be sure to measure each guide and valve

combination individually. NOTE
NOTE Carbon Clean Fuel Treatment (2871326) can be used
to help remove carbon deposits.
The valve guides cannot be replaced.
Do not use a metal scraper, a coarse wire brush or
abrasive cleaners to clean the cylinder head. Damage
may result.
VALVE SEALING TEST
1. Clean and dry the combustion chamber area. 2. Visually inspect cylinder head gasket surface and
combustion chamber for cracks or damage. Pay
2. Pour a small amount of clean solvent into each close attention to the areas around spark plug and
intake port q and check for leakage around the valve seats.
valves. The valve seats should hold fluid with no
seepage.
3. Repeat for exhaust valves by pouring fluid into each
exhaust port w.
VALVE SEAT RECONDITIONING Renewing Valve Seats

Valve seat reconditioning should be performed by a 1. Install pilot into valve guide.
technician proficient in cylinder head reconditioning
techniques. Reconditioning techniques vary, so follow 2. Apply cutting oil to valve seat and cutter.
the instructions provided by the valve reconditioning 3. Place 46° cutter on the pilot and make a light cut.
equipment manufacturer. Do not grind seats more than
necessary to provide proper seat surface, width, and 4. Inspect the cut area of the seat:
contact point on valve face. * If the contact area is less than 75% of the
circumference of the seat, rotate the pilot 180° and
CAUTION make another light cut.
Wear eye protection or a face shield during cylinder * If the cutter now contacts the uncut portion of the
seat, check the pilot. Look for burrs, nicks, or runout.
3
head disassembly and reassembly.
If the pilot is bent it must be replaced.
* If the contact area of the cutter is in the same place,
Valve Seat Inspection
the valve guide is distorted from improper
Inspect valve seat in cylinder head for pitting, burnt installation.
spots, roughness, and uneven surface. If any of the
* If the contact area of the initial cut is greater than
above conditions exist, the valve seat must be
75%, continue to cut the seat until all pits are
reconditioned. If the valve seat is cracked the cylinder
removed and a new seat surface is evident.
head must be replaced.
Valve seat width and point of contact on the valve face is NOTE
very important for proper sealing. The valve must contact Remove only the amount of material necessary to
the valve seat over the entire circumference of the seat, repair the seat surface.
and the seat must be the proper width all the way
around. If the seat is uneven, compression leakage will
result. If the seat is too wide, seat pressure is reduced, 5. To check the contact area of the seat on the valve
causing carbon accumulation and possible compression face, apply a thin coating of Prussian Blue paste to
loss. If the seat is too narrow, heat transfer from valve to the valve seat. If using an interference angle (46°)
seat is reduced. The valve may overheat and warp, apply black permanent marker to the entire valve
resulting in burnt valves. face (A).
6. Insert valve into guide and tap valve lightly into place
a few times.
7. Remove valve and check where the Prussian Blue Intake Seat Cutter Diameter:
indicates seat contact on the valve face. The valve 1.172 in. (29.793 mm)
seat should contact the middle of the valve face or
slightly above, and must be the proper width.
NOTE
When using an interference angle, the seat contact
point on the valve will be very narrow, and is a normal
condition. Look for an even and continuous contact
point all the way around the valve face (A).
Valve Seat Angles

1 - 17°
2 - 45°
3 - 70°
Exhaust Seat Cutter
Diameter:
0.956 in. (24.294 mm)
MEASUREMENT
Valve Seat Width:
8. Clean all filings from the area with hot soapy water.
Intake: Rinse and dry with compressed air.
Std.: .0393" (1.00 mm)
9. Lubricate valve guides with clean engine oil and
Service Limit: .0551" (1.4 mm) apply oil or water based lapping compound to the
face of the valve.
Exhaust: NOTE
Std.: .0393” (1.00 mm) Lapping is not required if an interference angle
Service Limit: .0758" (1.9 mm) reconditioning method is used.
* If the indicated seat contact is at the top edge of the 10. Insert the valve into its respective guide and lap
valve face and contacts the margin area (B) it is too using a lapping tool or a section of fuel line
high on the valve face. Use the 30° cutter to lower connected to the valve stem.
the valve seat. 11. Rotate the valve rapidly back and forth until the cut
* If too low, use the 70° cutter to raise the seat. When sounds smooth. Lift the valve slightly off of the seat,
contact area is centered on the valve face, measure rotate 1/4 turn, and repeat the lapping process. Do
seat width. this four to five times until the valve is fully seated,
* If the seat is too wide or uneven, use both top and and repeat process for the other valves.
bottom cutters to narrow the seat. 12. Thoroughly clean cylinder head and valves.
* If the seat is too narrow, widen using the 45° cutter
and re-check contact point on the valve face and
seat width after each cut.
CYLINDER REMOVAL 4. Inspect cylinder for taper and out of round with a
1. Remove and discard the head gasket q. telescoping gauge or a dial bore gauge. Measure in
two different directions, front to back and side to
2. Position the cam chain and guides vertically. side, on three different levels (1/2" down from top, in
3. Tap cylinder w lightly with a plastic hammer in the the middle, and 1/2” up from bottom).
reinforced areas only until loose.
4. Rock cylinder forward and backward and lift it from
the crankcase, supporting piston r and connecting
rod.
5. Remove the cylinder from the engine.
3
5. Record measurements taken in Step 4. If cylinder is

tapered, or out of round beyond .001, cylinder must
6. Remove and discard cylinder base gasket e. be re-bored oversize, or replaced.
CYLINDER INSPECTION Cylinder Taper

1. Remove all gasket material from the cylinder sealing .00078 in. / 0.020 mm
surfaces.
Cylinder Out of Round
2. Inspect the top of the cylinder for warpage using a .00078 in. / 0.020 mm
straight edge and feeler gauge.
Standard Bore Size:

3.07 +/- 0.0003″ (78.0 +/- 0.008 mm)
PISTON REMOVAL
1. Note piston directional indicator “∆” positioned
toward the magneto side of engine.
2. Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston
slightly with a heat gun.
CAUTION
Do not apply heat to the piston rings, they may lose
radial tension.
Cylinder Warpage:
.002 in. / 0.05 mm 3. Remove top ring.
*Using a piston ring pliers: Carefully expand ring
3. Inspect cylinder for wear, scratches, or damage. and lift it off the piston.
CAUTION PISTON / ROD INSPECTION

Do not expand the ring more than the amount 1. Measure piston pin bore inside diameter I.D.(1).
necessary to remove it from the piston.
*By hand: Placing both thumbs as shown, spread

the ring open and push up on the opposite side.
Piston Pin Bore I.D: 0.7244 - 0.7401″ (18.4 - 18.8 mm)
2. Measure piston pin O. D (2). Replace piston and/or

4. Repeat procedure for second ring. piston pin if out of tolerance.
5. Remove oil control ring top rail first, then bottom rail.
6. Remove oil control ring expander.
PISTON-TO-CYLINDER CLEARANCE
1. Measure the outside diameter of the piston 9.5 mm
up the skirt and at a right angle to the direction of the
piston pin.
Piston Pin O.D.:

Std:0 .724 –0 .740″ (18.4 – 18.8 mm)
Service Limit:0 .710″ (18.036 mm)
2. Subtract this measurement from the maximum

cylinder size measurement from cylinder inspection.
Piston to Cylinder Clearance:
.0003 - .002″ (.008 - .062 mm)
Piston O.D.:
3.068 - 3.07″ (77.946 – 77.984 mm)
3. Measure connecting rod small end ID. Inspect PISTON RING INSTALLED GAP
bearing surface for damage. 1. Place each piston ring inside cylinder. Use a piston
to push the ring squarely into place TBD” (mm) down
from the cylinder head gasket surface.
2. Measure installed gap with a feeler gauge at location
(A).
Piston Pin Degree of Fit:

Pin should be a push-fit by hand with piston at
room temperature or warmed slightly. specification
Connecting Rod Small End ID:
Std.: 0.7086 - 0.7093″ (18.000 - 18.018 mm)
NOTE
Always check piston ring installed gap after re-boring a
cylinder or when installing new rings.
ENGINE ASSEMBLY - TOP END

PISTON RING INSTALLATION
Piston Ring Identification / Orientation
Install the rings in the following orientations:
Piston Ring End Gap Positions

Install rings with the end gaps in the following locations:
1. Top Ring
2. Second Ring
3. Oil Control Expander (PTO Side)
1. Mark faces UP 4. Upper Oil Control Rail
2. Top Ring 5. Lower Oil Control Rail
3. Second Ring 6. Arrow points to MAG side of engine.
4. Oil Control Expander Ring Installation
5. Oil Control Rails 1. Place the lower oil control ring expander in oil ring
groove. Rotate expander in groove until butt ends
NOTE are on PTO side of piston (3).
Apply clean engine oil to all ring surfaces and ring lands
upon installation. Always check piston ring installed gap NOTE
before rings are installed on piston (see “Piston Ring Ends must butt squarely together and must not overlap.
Installed Gap”, page 3.57). Clean accumulated carbon
from piston ring grooves and oil ring lube holes if piston 2. Install lower rail with end gap positioned as shown in
has been in service. illustration (5).
3. Install upper rail with end gap positioned as shown at
(4).
4. Install second ring with marking facing top of piston.
Rotate ring to position the end gap toward intake
side of piston as shown (2).
5. Install top ring with mark facing top of piston. Rotate
ring to position the end gap toward exhaust side of
piston as shown (1).
6. Be sure top and second rings rotate freely in their
grooves and do not bind when compressed by hand.
PISTON / CONNECTING ROD ASSEMBLY CAUTION

IMPORTANT DO NOT apply heat to piston rings or a loss of
radial tension could result.
If installing the piston onto the connecting rod, you
cannot use special tools: PV-43570–1 (Piton Ring
Compressor Pliers) and PA-51457 (Piston Ring Band)
to compress the rings when installing the cylinder. The
rings must be fitted into the cylinder by hand.
1. Lubricate connecting rod small end, piston pin bore

and piston pin with engine oil. 3
CAUTION
Do not re-use circlips. Circlips become deformed during
the removal process.
Do not compress the new clip more than necessary to
prevent loss of radial tension. Severe engine damage
may result if circlips are re-used or deformed during
installation.
5. Install the remaining circlip q with gap at the 12:00
2. Install a new piston circlip q into the MAG (stator) position. Push the piston pin in both directions to
side of piston with the gap at the 12:00 position. make sure the clips are properly seated in the
3. When installing the piston, the piston marking “∆” is groove.
points towards the MAG (stator) side of the engine.
CYLINDER INSTALLATION – PISTON
INSTALLED ON CONNECTING ROD
1. Clean base gasket sealing surface on cylinder and
crankcase to remove all oil, grease, or old sealant.
2. Install a new base gasket.
4. Place piston w on connecting rod r. Install piston

pin e through connecting rod r and piston until it
seats against the previously installed piston circlip.
NOTE
Do not tap on pin or cause any sideways force to NOTE
connecting rod. Warm piston crown with a heat gun if Base gasket and surfaces must be dry and oil free.
pin cannot be installed by hand, or use a piston pin Match gasket and deck profiles during assembly. If
installation tool. gasket is installed incorrectly, it will hang over the edge
of the crankcase.
3. Apply clean engine oil to cylinder bore and bottom

tapered portion of cylinder sleeve.
4. Verify all ring end gaps are correctly located on the
piston. Place cam chain and guides in alignment with
chain tunnel.
5. Carefully compress rings with fingers and install 2. Install a new piston circlip into the MAG (stator) side
cylinder with a slight front to back rocking motion of piston with the gap at the 12:00 position.
until all rings are captive in cylinder and past the
taper of the sleeve. NOTE
6. Push cylinder q downward until fully seated on base An arrow mark denotes the MAG (stator) side of the
gasket. piston.
7. Hold the cylinder in place and rotate the engine and

position the piston at TDC.
3. Verify all ring gaps are correctly located on the piston.
NOTE
4. Carefully install the Piston Ring Band (PA-51457)
If cam chain and flywheel are installed (top end work around all of the rings on the piston. Secure the band
only is being performed) hold cam chain tight while with the Compressor Pliers (PV-43570–1).
rotating the engine to avoid damage to the chain, drive
sprocket teeth, or tensioner blade.
CYLINDER INSTALLATION - PISTON IN

CYLINDER
The piston and cylinder can be installed onto the engine
as an assembly. Using this method, special tools: PV-
43570–1 (Piston Ring Compressor Pliers) and PA-51457
(Piston Ring Band) can be used to compress the rings
when installing the piston into the cylinder.
1. Clean the cylinder bore and piston assembly. Apply a
light film of clean engine oil to the cylinder bore and
piston.
NOTE
Orientate band tool so that open end is opposite the
MAG side of the piston.
5. Carefully install the piston into the bottom of the 8. Install a new base gasket.
cylinder.
NOTE
NOTE Base gasket and surfaces must be dry and oil free.
Ring band and compression pliers tools not shown in Match gasket and deck profiles during assembly. If
image. gasket is installed incorrectly, it will hang over the edge
of the crankcase.
6. Install the piston deep enough into the cylinder so
that all of the piston rings are captured inside the 9. Verify the connecting rod is at TDC.
cylinder. Note there is a relief cut q into the PTO side 10. Install the cylinder / piston assembly onto the engine.
of the cylinder to access the piston pin and circlip. Stop when the connecting rod piston pin bore is
aligned with the piston pin bore.
7. Remove the piston ring band tool from the piston.
11. Lubricate the piston pin with clean engine oil. Install CYLINDER HEAD ASSEMBLY
the piston pin until it seat against the MAG side
circlip. NOTE
Assemble the valves one at a time to maintain proper
order.
CAUTION
Wear eye protection during cylinder head disassembly
and reassembly or when working with the valve springs.
1. Apply engine oil to valve guides and seats.

2. Lubricate the valve stems with clean engine oil.
3. Install the valve u in the cylinder head, through the
guide.
12. Install the remaining circlip with gap at the 12:00

position. Push the piston pin in both directions to
make sure the clips are properly seated in the groove.
4. Carefully install a new valve seat/seal t, y on the

valve guide with a rotating motion. Push firmly until
seated in retaining groove and square with the guide
13. After the piston pin and circlip are installed, slide the 5. Dip the valve spring r and retainer w in clean
cylinder down onto the crankcase. engine oil.
6. Install the valve spring with tightly spaced coils CYLINDER HEAD INSTALLATION
facing down toward the cylinder head.
NOTE
Head gasket and surfaces must be DRY and oil free.
Use care during assembly to keep oil and finger prints
off of gasket.
1. The four cylinder studs cannot be re-used after the

cylinder head cap nuts are removed. Install new
studs using commercially available stud installation
tool prior to cylinder head installation. Torque new
studs to specification.
3
NOTE
Stud Thread Pitch: M8 x 1.25
TORQUE
NOTE Cylinder Head Studs:
Valve springs to be installed with the loosely spaced
coils q facing up.
2. Prepare cylinder head gasket sealing surfaces by
cleaning thoroughly to remove all residue. The new
7. Place the valve retainer w on the spring. head gasket must be installed clean and dry, free
8. Compress the valve spring with valve spring from oil or grease.
compressor (PV-1253) and valve spring compressor
adapter (PU-51038). Compress spring only enough
to allow split keeper installation.
NOTE
To prevent damage to the valve seals, do not compress
the valve spring more than necessary to install the
keepers.
9. Install split keepers e with gap even on both sides.

10. Repeat this procedure for remaining valves.
11. Exercise each valve through its travel to ensure the
valve keepers are seated correctly.
12. Lubricate and install the valve tappet for each valve
in the order they were removed. NOTE
NOTE Install head gasket with “Down” facing cylinder. The
gasket will not fit around the alignment pins if installed
If any valve train components were replaced, refer to
incorrectly.
“Valve Clearance Adjustment”, page 3.68
procedure prior to “Camshaft Installation / Timing”,
page 3.64 procedure. 3. Guide cam chain through a new head gasket r and
install the gasket on the cylinder, locating it on the
alignment pins.
4. Carefully set the cylinder head e in place on cylinder
studs and alignment pins.
5. Install and finger tighten the new cylinder head bolts
q evenly.
6. Install and finger tighten the cylinder head nuts w
evenly.
7. Torque the cylinder head nuts in sequence to 3. Lubricate all camshaft lobes and bearing journal
specifications. surfaces with Polaris PS-4 engine oil prior to
installation.
4. Wrap the cam chain around the exhaust cam
sprocket and hold the exhaust cam in its current
position.
TORQUE
Cylinder Head Torque Procedure: 5. Place the cam carrier into the cylinder head and
verify the exhaust cam gear timing marks are aligned
Step 1:Torque the (4) M8 Nuts in Sequence to 15
as shown below.
ft-lbs (20 Nm)
Step 2:Torque the (4) M8 Nuts in Sequence 180°
(1/2 turn)
Step 3:Torque the Outer M6 Head Bolts to 9 ft-
lbs (12 ± 1 Nm)
CAMSHAFT INSTALLATION / TIMING

NOTE
If any valve train components were replaced, refer to:
Valve Clearance Check / Adjustment, page 3.68.
1. Rotate the engine and position the piston at TDC.

2. Install the Camshaft Timing Tool (PA-51423) into the 6. Carefully install the intake cam gear.
alignment holes on each camshaft.
7. Verify that the timing marks are in alignment as 9. Install cam carrier bolts and torque in sequence to
shown below. specification.
NOTE
gasket surface and the exhaust cam sprocket should
8. Verify cam timing is correct and the piston is at TDC

q.
TORQUE
Camshaft Carrier Bolts:
7 ft-lbs (10 Nm)
10. Insert Cam Intake Tool (PA-51430) onto Cam Intake 15. Install the cam chain tensioner y with a new gasket
gear. Secure Cam Intake Tool using a ratchet. u into the cylinder and torque screws f to
Torque intake camshaft sprocket bolt to specification. specification.
TORQUE
TORQUE
Camshaft Chain Tensioner Screws:
Intake & Exhaust Camshaft Sprocket Bolt: 6 ft-lbs (8 Nm)
14 ft-lbs (19 Nm)
16. Install the spring a and screw d into the barrel.
11. Remove the (PA-51430) from the intake gear and Torque screw to specification.
(PA-51423) from the cam carrier.
12. Obtain the cam chain tensioner assembly.
17. Rotate crankshaft through two revolutions and verify

camshaft timing is correct.
13. Remove the screw d from the end of the barrel.
Extract the spring a and inspect the O-ring s. TORQUE
Replace O-ring if damaged. Camshaft Chain Tensioner Spring Screws:
14. Push the detent o down and push the ram i into 6 ft-lbs (8 Nm)
the housing.
CAMSHAFT TIMING - QUICK REFERENCE
VALVE CLEARANCE ADJUSTMENT 4. Reference the valve clearance measurement

The Valve Clearance Adjustment Procedure only outlines recorded for that valve, along with the 3 digit tappet
how to disassemble the camshaft / carrier assembly and number.
tappet replacement. To measure the valve clearance, 5. Reference the Intake and Exhaust Valve Lash –
reference the Valve Clearance Inspection Procedure. Tappet Selection Tables. See Intake Valve Lash -
Tappet Selection Matrix, page 3.70 or Exhaust Valve
NOTE Lash - Tappet Selection Matrix, page 3.71.
Always inspect valve clearance prior to camshaft
6. Install the correct tappet.
installation or final engine assembly. The following
procedure assumes the camshaft / carrier assembly is NOTE
already installed on the engine. If the camshaft / carrier
assembly is already removed from the cylinder head, it Lubricate the new tappet with a light film of engine oil
must be installed using the specified nut and screw prior to installation.
torque values to obtain accurate valve clearance
measurements. 7. Repeat steps 2-6 until all required valves have been
adjusted.
1. Remove the valve cover and camshaft / carrier 8. Reinstall the camshaft / carrier and valve cover.
assembly from the engine. See: Camshaft / Carrier
Removal , page 3.44. 9. If previously removed, reinstall the spark plug.
Torque spark plug to specification.
2. Remove the valve tappet(s) that require replacement
as a result of the valve clearance inspection. TORQUE
Spark Plug:
9 ft-lbs (12 Nm)Do Not Apply Anti-seize
10. Inspect the valve cover seal and replace if

necessary.
11. Install NEW isolators on the valve cover bolts. Install
the valve cover and the four T40 bolts. Torque bolts
to specification.
TORQUE
Valve Cover Bolts:
7 ft-lbs (10 Nm)
3. Record the 3 digit number on the bottom of each

tappet.
NOTE
This engine features one-piece tappets / shims. The
shims are not removable from the tappets.
VALVE COVER INSTALLATION

1. Prepare valve cover sealing surfaces by cleaning
thoroughly to remove all residue.
NOTE
Carefully pass the spark plug hole section q of the
valve cover seal under the cam carrier bridge w to
remove or install the seal.
2. Install the three valve cover shoulder bolts w and

new isolators e using a T40 driver.
IMPORTANT
New isolators are required once removed.
3. Torque valve cover bolts to specification.

TORQUE
Valve Cover Bolts
7 ft-lbs (10 Nm)
4. Install the spark plug q and torque to specification.
TORQUE
Spark Plug:
325 INTAKE VALVE LASH - TAPPET SELECTION MATRIX

Tappet Thickness Example: 460 = 4.600 mm, 462 = MEASUREMENT
4.625, 465 = 4.650, and 468 = 4.675. Part Number:
3022584-XXX (X’s represent 3 digits on tappet) Intake Valve Clearance (cold):
.005 ± .002″ (0.125 ± .050 mm)
Existing Valve Lash Tappet Marking (3 digits on tappet)

458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540
Correct Valve Lash Tappet Marking (3 digits on tappet)

0.000-0.024 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530
0.025-0.049 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532
0.050-0.074 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535
0.075-0.175
(Standard)
0.176-0.200 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542
0.201-0.225 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545
0.226-0.250 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548
0.251-0.275 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
Intake Valve Clearance Before Adjusting (mm)
0.276-0.300 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.301-0.325 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.326-0.350 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.351-0.375 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.376-0.400 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.401-0.425 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.426-0.450 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.451-0.475 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.476-0.500 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.501-0.525 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.526-0.550 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.551-0.575 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.576-0.600 502 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.601-0.625 505 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.626-0.650 508 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.651-0.675 510 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.676-0.700 512 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.701-0.725 515 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.726-0.750 518 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.751-0.775 520 522 525 528 530 532 535 535 538 540 542 545 548 550
0.776-0.800 522 525 528 530 532 535 535 538 540 542 545 548 550
0.801-0.825 525 528 530 532 535 535 538 540 542 545 548 550
0.826-0.850 528 530 532 535 535 538 540 542 545 548 550
0.851-0.875 530 532 535 535 538 540 542 545 548 550
0.876-0.900 532 535 535 538 540 542 545 548 550
0.901-0.925 535 535 538 540 542 545 548 550
0.926-0.950 535 538 540 542 545 548 550
0.951-0.975 538 540 542 545 548 550
0.976-1.000 540 542 545 548 550
325 EXHAUST VALVE LASH - TAPPET SELECTION MATRIX

Example: MEASUREMENT
Tappet Thickness Example: 460 = 4.600 mm, 462 = Exhaust Valve Clearance (cold):
4.625, 465 = 4.650, and 468 = 4.675. Part Number: 0.014 ± 0.002″ (0.350 ± .50 mm)
3022584-XXX (X’s represent 3 digits on tappet)

480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540

0.000-0.024 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 3
0.025-0.049 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510
0.050-0.074 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512
0.075-0.099 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515
Exhaust Valve Clearance Before Adjusting (mm)
0.100-0.124 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518
0.125-0.149 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520
0.150-0.174 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522
0.175-0.199 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525
0.200-0.224 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528
0.225-0.249 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530
0.250-0.274 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532
0.275-0.299 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535
0.300-0.400
(Standard)
0.401-0.425 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.426-0.450 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 548
0.451-0.475 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 548 550
0.476-0.500 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 548 550
0.501-0.525 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 548 550
0.526-0.550 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 548 550
0.551-0.575 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 548 550
0.576-0.600 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 548 550
0.601-0.625 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 548 550
0.626-0.650 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 548 550
0.651-0.675 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545 548 550
0.676-0.700 512 515 518 520 522 525 528 530 532 535 538 540 542 545 548 550
0.701-0.725 515 518 520 522 525 528 530 532 535 538 540 542 545 548 550
0.726-0.750 518 520 522 525 528 530 532 535 538 540 542 545 548 550
0.751-0.775 520 522 525 528 530 532 535 538 540 542 545 548 550
0.776-0.800 522 525 528 530 532 535 538 540 542 545 548 550
0.801-0.825 525 528 530 532 535 538 540 542 545 548 550
0.826-0.850 528 530 532 535 538 540 542 545 548 550
0.851-0.875 530 532 535 538 540 542 545 548 550
0.876-0.900 532 535 538 540 542 545 548 550
ENGINE DISASSEMBLY / INSPECTION - LOWER END

CRANKCASE DISASSEMBLY 7. Hold flywheel special service tool PU-51220 and
remove flywheel nut and washer. Discard the
NOTE flywheel nut and replace for assembly.
The engine top end, starter motor, stator cover, starter
drive, flywheel, stator, cam chain, oil pump and
sprockets can be serviced with the engine installed in
the vehicle.
STATOR COVER / FLYWHEEL REMOVAL

bolts. See Engine to Transmission Coupler Service,
page 3.40.
NOTE
To properly remove the stator cover, the engine must be
tilted away from the transmission coupler. The coupler
itself doesn’t require removal.
NOTE
The flywheel nut has standard rotation (right hand)
CAUTION threads.
The flywheel contains powerful magnets. Use caution
when removing the stator cover. 8. Back the center screw of flywheel puller PA-49316
DO NOT place fingers between cover and crankcase at completely out and screw puller onto flywheel
any time during the removal process or injury could completely.
result.
2. Disconnect stator harness connector.

3. Disconnect CPS connector.
4. Remove the engine oil dipstick.
5. Remove stator cover fasteners.
6. Remove starter drive gear w and shaft q. Inspect
gear teeth for damage. Inspect fit of shaft inside gear
and replace gear assembly if clearance is excessive.
Inspect shaft and shaft bearing surfaces in case and
stator housing for wear.
9. Tighten center bolt of tool PA-49316 and remove

flywheel.
STATOR REMOVAL 5. Inspect surface of flywheel gear hub q for wear,

galling, or uneven surface.
NOTE
Test stator wire continuity before removing it from the
housing.
1. Remove the stator cover.
CAUTION
when removing the stator cover. 3
DO NOT place fingers between cover and crankcase at
any time during the removal process or injury could
result.
2. Remove and discard the stator cover gasket.
CAUTION
6. Inspect crankshaft bearing surface for abnormal
Be sure engine coolant does not contaminate the wear.
engine oil during stator cover service.
7. Remove the w one-way clutch retaining bolts.
3. Remove the 3 bolts e that secure the stator q to the
stator cover w.
8. Remove clutch e and inspect both sides of drive

rollers r and roller contact surface t inside hub for
4. Remove the 2 bolts that secure the stator wire wear, damage, or uneven surface.
routing bracket r to the stator cover.
5. Remove the stator q from the stator cover.
STARTER ONE-WAY CLUTCH INSPECTION

1. Remove flywheel as outlined in this chapter.
2. Place flywheel on work bench. Grasp gear and rotate
clockwise. It should turn smoothly without binding.
3. Rotate gear counterclockwise. The gear should
immediately lock in position and not slip.
4. Remove starter gear from the flywheel assembly.
9. Inspect drive surface of starter gear and bearing OIL PUMP REMOVAL
surface for wear, damage, or uneven surface. If any
starter clutch component is worn or damaged,
replace clutch, clutch hub, and starter gear.
q Screw u Washer
w Cover, Oil Pump i Retaining Ring
e Gerotor o Washer
r Pin, Solid a Piston / Spring
t Shaft, Oil Pump s Oil Seal
y Gerotor
1. Remove the stator cover. 5. Coat the piston with clean engine oil and insert it into
the stator cover until fully seated.
2. Remove the bolts q securing the oil pump cover to
the stator cover.
3. Grasp the oil pump shaft t and pull it outward to
remove the shaft, oil pump cover w and inner oil
pump gerotor.
NOTE
The gerotor set has w orientation dots that must be
installed inward upon assembly.
3
4. Remove the center gerotor e , pin r and shaft t
from the oil pump cover.
NOTE
There is a spacer in between the inner oil pump gerotor
and the oil pump cover.
6. Install the spring, washer and retaining ring.
5. Remove the oil pump gerotor that is in the stator
cover (if needed). STATOR COVER OIL SEAL INSPECTION
6. Clean the gerotor to remove oil. Inspect the oil seal q whenever the stator cover is
removed from the engine. Remove and replace if wear is
7. Inspect surfaces of pump cavity in stator cover and found.
surface of pump cover for scoring or wear.
8. Inspect gerotor for scoring or other damage. Replace
parts as a set if damaged.
OIL PRESSURE REGULATOR (BYPASS)

VALVE INSPECTION
The oil pressure regulator (bypass) valve is located in the
stator cover.
1. Remove the retaining ring q securing the oil
pressure regulator piston in the stator cover.
2. Remove the washer w, spring e and piston r.
3. Replace the oil pressure regulator piston if it binds,
sticks or does not operate smoothly.
When installing a new seal, press seal in with lips facing
4. Thoroughly clean the piston and bore. towards cover. Press until seal is fully seated in bore w.
BALANCE SHAFT REMOVAL / INSPECTION 10. Inspect / replace the balance shaft bearings in the
1. Rotate crankshaft to align the timing marks as shown upper crankcase. See: PTO and MAG Side
below. Crankcase Bearing Service, page 3.78.
2. Install Crank-Balance Shaft Holder PA-51424 t onto NOTE

the balance shaft and crankshaft. Due to extremely close tolerances and minimal wear,
counterbalance shaft ball bearings must be inspected
visually and by feel. Look for signs of discoloration,
scoring or galling. Turn the inner race of each bearing.
The bearings should turn smoothly and quietly. The
outer race of each bearing should fit tightly in the
crankcase bore. The inner race should be firm with
minimal side to side movement and no detectable up
and down (radial) movement.
BALANCE SHAFT BEARING SERVICE

1. Remove the balance shaft assembly. See Balance
Shaft Removal / Inspection, page 3.76.
2. Remove the water pump seal q Refer to Water
3. Remove the balance shaft nut t and washer r. Pump Service - ACE, page ).
4. Remove Crank-Balance Shaft Holder PA-51424.

3. Remove the oil seal w from the PTO side of the
5. Remove the balance drive gear. upper engine case.
6. Remove the balance shaft retainer fasteners e and 4. Support the engine case on the MAG side in a
retainer w. suitable shop press. Carefully remove the balance
7. Remove the balance shaft from the crankcase. shaft out the mag side of the upper engine case.
NOTE
CRANKCASE SEPARATION
Tapping with a soft-faced hammer on the water pump
drive end of the shaft may be required. NOTE
Before the crankcase can be separated, be sure the
8. Inspect drive gear for broken or damaged teeth. entire top end, stator cover assembly and counter-
9. Inspect bearing surfaces for scoring or signs of wear. balance shaft assembly are removed from the engine
as outlined in this chapter.
1. Support the engine so oil sump cover side is facing

upward.
2. Remove the lower crankcase fasteners q. CRANKSHAFT INSPECTION

NOTE
The connecting rod uses plain bearings. The
connecting rod bearings are not serviceable. If ANY
excessive wear or movement is present or if the rod
does not rotate on the crankshaft freely, the crankshaft
assembly must be replaced.
1. Use a feeler gauge to measure the connecting rod

big end side clearance q. 3
3. Separate crankcase halves by tapping with a soft

faced hammer in reinforced areas and lift the lower
crankcase half off the upper crankcase half.
NOTE
The cylinder head studs w must be replaced any time
the cylinder head nuts are loosened.
Use a commercially available stud removal tool. The
stud thread pitch is M8 x 1.25.
TORQUE Connecting Rod Big End Side Clearance:

0.00590-.01771″ (.15 - .45 mm)
2. Measure the connecting rod small end I.D. w.
CRANKSHAFT REMOVAL
1. Remove the cylinder head.
2. Remove the cylinder and piston.
3. Remove the stator cover and flywheel.
4. Remove the water pump cover and water pump
impeller.
5. Remove the balance shaft assembly.
6. Remove the engine oil sump cover.
7. Separate the engine case halves.
8. Place the upper engine case cylinder side down and
lift the crankshaft assembly from the engine.
Small End I.D. Standard:

.7086 - .709″ (18.000 - 18.018 mm)
Service Limit: .710″ (18.036 mm)
3. Place the crankshaft in a truing stand or V-blocks PTO AND MAG SIDE CRANKCASE
and measure the runout where indicated below with BEARING SERVICE
a dial indicator.
Bearing Inspection
1. Remove crankshaft assembly and discard PTO side
crankshaft oil seal q.
NOTE
The PTO w and MAG e side main bearings are not
serviceable. Crankshaft replacement is required if the
bearings are damaged or have excessive wear.
Maximum Runout:
Mag side e - 0.002″ (0.05 mm)
PTO side r - 0.002″ (0.05 mm)
NOTE
Due to extremely close tolerances and minimal wear,
the bearings must be inspected visually, and by feel.
Look for signs of discoloration, scoring or galling. Turn
the outer race of each bearing. The bearings should
turn smoothly and quietly. The outer race of each
bearing should fit tightly in the crankcase. The inner
race should be firm with no side to side movement and
no detectable up and down movement.
OIL PICKUP ASSEMBLY INSPECTION

The oil pickup assembly is located in the oil sump cover
e.
1. Remove and discard the oil inlet seal q. Verify the

oil seal is not inside the pickup bore in the
crankcase.
2. Apply white lithium grease to the ID and OD of a a
new oil inlet seal. Install new oil inlet seal into the
crankcase oil pickup bore.
3. Remove the oil pickup assembly fasteners w from
the oil sump cover e.
4. Thoroughly clean the pickup assembly.
5. Inspect the oil pickup assembly for cracks and
excessive wear. Replace if necessary.
6. After cleaning and inspecting pickup assembly,
install it into the oil sump and torque screws to
specification.
TORQUE
Oil Pickup Screws:
5 ft-lbs (7 Nm)
CRANKCASE INSPECTION
1. Remove all traces of gasket sealer from the
crankcase mating surfaces. Inspect the surfaces
closely for nicks, burrs or damage.
2. Be sure alignment pins are in place where used.
3. Be sure oil passages are clean and free of any
cleaning solvent.
ENGINE ASSEMBLY - LOWER END 7. Be sure crankshaft is fully seated and rotates
smoothly.
CRANKCASE ASSEMBLY
NOTE
1. Clean upper and lower crankcase sealing surface to
remove all old sealant and oil residue. The crankshaft PTO seal can be replaced with the
engine installed in the chassis. The engine does not
2. Place crankcase cylinder side down on a sturdy work have to be removed and the crankcase does not have
bench. to be separated to replace the crankshaft seal.
3. On the upper crankcase, install the chain guides.
Torque fasteners to specification. 8. Apply a thin film of Crankcase Sealant (PN 2871557)
evenly to the clean and oil-free lower crankcase
mating surface.
TORQUE
Camshaft Chain Guide Screws:
7 ft-lbs (10 Nm)
NOTE Crankcase Sealant:

PN 2871557
The chain guides must be installed before assembling
the upper and lower crankcases. 9. Verify alignment pins location and install lower
crankcase onto upper crankcase assembly while
4. Lubricate all crankcase bearings with engine oil. pressing the PTO seal firmly against the bearing
5. Slide a new crankshaft seal over the PTO end of the race.
crankshaft with numbers facing OUT. Be sure seal lip 10. Install and torque crankcase bolts in sequence to
does not fold back when moving over the crankshaft specification:
flange.
TORQUE
CAUTION Crankcase Screws::
Wipe the crankshaft seal O.D. with isopropyl alcohol 7 ft-lbs (10 Nm) (In Sequence)
before installation.
Do not lubricate the crankcase seal O.D.
6. Loosely install the cam chain retainer plate and

screw into the lower crankcase.. Install the cam
chain onto the drive gear on the crankshaft. Install
the crankshaft into the lower crankcase.
NOTE
The cam chain must be installed on the crankshaft
during crankshaft installation into the lower crankcase.
Once the crankcases are mated and the retainer plate
secured, the cam chain will be held in place on the
crankshaft.
11. Torque the cam chain retainer plate q screw to BALANCE SHAFT INSTALLATION / TIMING
specification. 1. Position balancer shaft q in the crankcase.
TORQUE 2. Install balance shaft bearing retainer w and torque

fasteners e to specification.
Cam Chain Retainer Screw:
7 ft-lbs (10 Nm) TORQUE
Balance Shaft Retainer Fasteners:
12. Turn the assembled crankcase over and support the 7 ft-lbs (10 Nm)
connecting rod in an upright position.
13. Install new crankcase studs into crankcase using a 3. Align keyway and install balancer shaft gear on the
commercially available stud installation tool. balancer shaft.
4. Rotate crankshaft to align the timing marks y as
shown below.
NOTE
Stud Thread Pitch: M8 x 1.25
TORQUE
14. Proceed with installing the top-end of the engine.
5. Install Crank-Balance Shaft Holder PA-51424 t onto 4. Torque screws to specification.

the balance shaft and crankshaft.
6. Install washer r , nut t and torque balance shaft

nut to specifications. TORQUE
One Way Clutch Retaining Bolts:
TORQUE
9 ft-lbs (12 Nm)Apply Loctite® 272™
Balance Shaft Nut:
132 ft-lbs (180 Nm)
FLYWHEEL INSTALLATION
1. Clean the threads q, taper w and flat e of
STARTER ONE-WAY CLUTCH crankshaft to remove all oil or grease.
INSTALLATION
1. Install one-way clutch in clutch hub with flange of
clutch q facing the flywheel.
NOTE
The one-way clutch can be installed into the hub
incorrectly. This will cause engine cranking issues.
2. Clean screw threads in flywheel to remove all oil or

grease.
3. Apply Loctite® 272™ on the one way clutch retaining
bolts threads w. Place hub on flywheel and install
bolts.
2. Clean flywheel taper r to remove all oil or grease. 6. Align the flywheel keyway with flywheel key on the
crankshaft.
7. Apply a drop of Loctite 641 (Yellow) to the tapers
before assembly. Loctite 603 (Green) can be used if
641 is not available.
8. By hand, lightly press the flywheel inward while
rotating the starter gear counter clock-wise. Fully
install the flywheel until seated on the crankshaft
taper.
3. Apply a small amount of PS-4 engine oil to the flat

area t on the MAG side crankshaft. DO NOT apply
engine oil to the crankshaft taper.
9. Install the flywheel washer.

10. Hold flywheel with commercially available strap
wrench.
11. Torque new flywheel nut to specification.
4. Rotate crankshaft so the flywheel key y is facing

upward.
5. Fully install starter gear onto the crankshaft as
shown.
TORQUE
Flywheel Retaining Nut:
133 ft-lbs (180 Nm)Torque to specification, back of
180 degrees, retorque to specification.
12. Install starter idler gear w and shaft q. 9. Install the q oil pump cover bolts and torque to
specification.
TORQUE
Oil Pump Cover Bolts:
7 ft-lbs (10 Nm)
STATOR / STATOR COVER INSTALLATION

1. Clean and degrease stator screws and threads in the
stator housing.
2. Clean mounting surfaces of stator q and housing w.
3. Apply crankcase sealant to edges of rubber stator
grommet.
4. Set the stator in housing and press wire grommet
into slot on housing.
OIL PUMP ASSEMBLY 5. Apply Loctite® 242™ to end (8-10 threads) of the
1. Clean and dry all parts thoroughly. Apply clean stator screws e and the wire routing bracket screws
engine oil to all parts. Do not use gasket sealer on r.
the pump cover mating surfaces.
6. Install a new stator cover gasket.
2. Align the gerotor according to the orientation dots.
7. Install the stator cover.
3. Place the drive pin e through the oil pump drive
shaft t. CAUTION
when installing the stator cover.
any time during the installation process or injury could
result.
8. Install the stator cover screws and torque to

specification.
4. Slide the gerotor e onto the drive shaft and lock

them into position on the drive pin.
5. Install the washer u onto the drive shaft.
6. Install the oil pump cover onto the shaft assembly.
7. Grasp the complete oil pump assembly by the drive
shaft and install the assembly into the stator cover.
8. Pack the voids of gerotor and relief valve bore with
white lithium engine assembly grease (Lubriplate TORQUE
#105 or equivalent).
Stator Cover BoltsStator to Cover Retaining Bolts:
TORQUE
Stator Wire Bracket Bolts:
ENGINE / COOLING SYSTEM TROUBLESHOOTING

ENGINE TROUBLESHOOTING Engine Idles But Will Not Accelerate
Spark Plug Fouling • Spark plug fouled/weak spark
• Broken throttle cable
• Spark plug cap loose or faulty • Obstruction in air intake
• Incorrect spark plug heat range or gap • Air box removed (reinstall all intake components)
• PVT system calibrated incorrectly/ components worn • Incorrect ignition timing
or mis-adjusted • Restricted exhaust system
• Fuel quality poor (old) or octane too high • Camshaft worn excessively
• Low compression
• Restricted exhaust Engine Has Low Power
• Weak ignition (loose coil ground, faulty coil, or stator)
• Restricted air filter (main or pre-cleaner) or breather • Spark plug fouled
system • Cylinder, piston, ring, or valve wear or damage (check
• Improperly assembled air intake system compression)
• Restricted engine breather system • PVT not operating properly
• Oil contaminated with fuel • Restricted exhaust muffler
• Camshaft worn excessively
Engine Turns Over But Fails To Start
Piston Failure - Scoring
• No fuel
• Dirt in fuel line or filter • Lack of lubrication
• Fuel will not pass through fuel valve • Dirt entering engine through cracks in air filter or ducts
• Fuel pump inoperative/restricted • Engine oil dirty or contaminated
• Tank vent plugged or pinched Excessive Smoke and Carbon Buildup
• Engine flooded
• Low compression (high cylinder leakage) • Excessive piston-to-cylinder clearance
• No spark (Spark plug fouled) ignition component • Wet sumping due to over-full crankcase
failure • Worn rings, piston, or cylinder
• Worn valve guides or seals
Engine Does Not Turn Over • Restricted breather
• Brake pedal not engaged • Air filter dirty or contaminated
• Dead battery Low Compression / Excessive Cylinder Leakage
• Starter motor does not turn
• Engine seized, rusted, or mechanical failure • Cylinder head gasket leak
• No valve clearance (cam wear)
Engine Runs But Will Not Idle • Cylinder or piston worn
• Restricted fuel supply • Piston rings worn, leaking, broken, or sticking
• Low compression • Bent valve or stuck valve
• Crankcase breather restricted • Valve spring broken or weak
• Valve not seating properly (bent or carbon
accumulated on sealing surface)
• Rocker arm sticking
Backfiring
• Fouled spark plug or incorrect plug or plug gap
• Intake system air leaks
• Exhaust system air leaks
• Valve sticking
• Ignition system faulty:
• Spark plug cap cracked / broken
• Ignition coil faulty
• Ignition or kill switch circuit faulty
• Poor connections in ignition system
• Ignition timing incorrect
• Sheared flywheel key
COOLING SYSTEM TROUBLESHOOTING

Overheating
• Low coolant level
• Air in cooling system
• Wrong type/mix of coolant
• Faulty pressure cap or system leaks
• Restricted system (mud or debris in radiator fins
causing restriction to air flow, passages blocked in
radiator, lines, pump, or water jacket, accident
damage)
• Lean mixture (vents, fuel pump or fuel valve) 3
• Fuel pump output weak
• Electrical malfunction
• Water pump failure/ Loose impeller
• Thermistor failure
• Cooling fan inoperative or turning too slowly (perform
current draw test)
• Low oil level
• Spark plug incorrect heat range
• Faulty hot light circuit
• Thermostat stuck closed or not opening completely
• Radiator is missing its internal diverter plate not
allowing coolant to flow through entire radiator
Temperature Too Low
• Thermostat stuck open
Leak at Water Pump Weep Hole
• Faulty water pump mechanical seal (coolant leak)
• Faulty pump shaft oil seal (oil leak)
3.2 570
GENERAL INFORMATION
SPECIAL TOOLS
PART
NUM- TOOL DESCRIPTION
BER
PW- Bench Mount Engine Stand Adapter
47053
PU-
Clutch Center Distance Tool
50658
PU-
Crankshaft Removal / Installation Tool Kit
50784
PU- Cylinder Holding & Camshaft Timing Plate
50563
PU- Engine Stand (2” Bore)
50624
PU- Engine Stand Adapter (Mounts To The
50824 Engine)
PU- Engine Stand Sleeve Adapter (Use With 2”
50625 Bore Stand)
PW- Engine Stand Sleeve Adapter (Use With
47054 2.375” Bore Stand)
PA- Flywheel Puller
49316
PU-
Oil Filter Wrench
50105
PV- Oil Pressure Gauge
43531
PU- Oil Pressure Gauge Adapter
50569
PA-
Stator Cover Removal Handles
49317
PV-1253 Valve Spring Compressor
PV- Valve Spring Compressor Adapter
43513-A
PU- Water Pump Mechanical / Oil Seal Installation
50689 Kit
Bosch Automotive Service Solutions: 1-800-345-2233
http://polaris.service-solutions.com/.
ENGINE LUBRICATION SPECIFICATIONS 2. Remove the seats and engine service panel.
3. Clean the area around the main oil gallery plug q,
FLUID CAPACITY
located on the oil filter adapter housing.
Oil Capacity
Approx. 2 Quarts (1.9 L)
Oil Filter Wrench
PU-50105 or 2.5″ (64 mm)
Oil Type
Polaris PS-4 Synthetic Engine Oil
Oil Pressure Minimum Specification
(using Polaris PS-4 at operating temperature) 3
10 PSI @ 1200 RPM (Minimum)
40 PSI @ 7000 RPM (Minimum)
OIL PRESSURE TEST

1. Attach the Oil Pressure Gauge Adapter to the Oil
4. Remove the plug and insert the oil pressure adapter.
Pressure Gauge.
5. Start engine and allow it to reach operating
temperature, monitoring gauge indication.
NOTE
Test results are based on the use of the recommended
engine oil (Polaris PS-4) at operating temperature, and
may vary considerably if any other oil is used or if
engine is not up to temperature.
6. Upon assembly, torque the crankcase gallery plug to

specification.
TORQUE
Oil Gallery Plug:
11 ft-lbs (15 Nm)
Oil Pressure Gauge Adapter: PU-50569

Oil Pressure Gauge: PV-43531
ENGINE OIL FLOW CHART
ENGINE SPECIFICATIONS
CAMSHAFT / CYLINDER HEAD / CYLINDER INCHES (MM)
Cam Lobe Height - Intake 1.5704" ± 0.0038" (39.89 ± 0.097 mm)
Cam Lobe Height - Exhaust 1.5405" ± 0.0038" (39.13 ± 0.097 mm)
Camshaft Journal O.D. - All (Standard) 0.9029" - 0.9037 " (22.933 - 22.954 mm)
Camshaft Journal O.D. - All (Service Limit) 0.9025" (22.923 mm)
Camshaft Journal Bore I.D. - All (Standard) 0.9055" - 0.9063" (23.000 - 23.021 mm)
Camshaft
Camshaft Journal Bore I.D. - All (Service Limit) 0.9072" (23.044 mm)
3
Camshaft Oil Clearance (Standard) 0.0018" - 0.0034" (0.046 - 0.088 mm)
Camshaft Oil Clearance (Service Limit) 0.0047" (0.121 mm)
Camshaft End Play (Standard) 0.0069" - 0.0128" (0.175 - 0.325 mm)
Camshaft End Play (Service Limit) 0.0157" (0.4 mm)
Cylinder Head - Surface Warp Limit 0.0024" (0.060 mm)

Cylinder Head
Cylinder Head - Standard Height 4.745" ± 0.0020" (120.53 ± 0.05 mm)
Valve Seat - Contacting Width - Intake (Standard) 0.0393" ± 0.0039" (1.0 ± 0.10 mm)
Valve Seat - Contacting Width - Intake (Service Limit) 0.0551" (1.4 mm)
Valve Seat Valve Seat - Contacting Width - Exhaust (Standard) 0.0590" ± 0.0039" (1.5 ± 0.10 mm)
Valve Seat - Contacting Width - Exhaust (Service Limit) 0.0748" (1.9 mm)
Valve Seat Angles 30.0° ± 1.5° / 45.0° ± 0.5° / 60.0° ± 1.5°
Valve Guide Valve Guide Inner Diameter 0.2165" - 0.2171" (5.500 - 5.515 mm)
Valve Lash (Cold) - Intake 0.006" ± 0.002" (0.152 ± 0.050 mm)
Valve Lash (Cold) - Exhaust 0.008" ± 0.002" (0.203 ± 0.050 mm)
Valve Stem Diameter - Intake 0.2155" - 0.2161" (5.475 - 5.490 mm)
Valve Stem Diameter - Exhaust 0.2147" - 0.2153" (5.455 - 5.470 mm)

Valve
Valve Stem Oil Clearance - Intake 0.0003" - 0.0015" (0.010 - 0.040 mm)
Valve Stem Oil Clearance - Exhaust 0.0011" - 0.0023" (0.030 - 0.060 mm)
Valve Stem Overall Length - Intake 3.7704" (95.77 mm)
Valve Stem Overall Length - Exhaust 3.7964" (96.43 mm)
Valve Spring Free Length (Standard) 1.7263" (43.85 mm)

Valve Spring
Valve Spring Free Length (Service Limit) 1.683" (42.75 mm)
Cylinder - Surface Warp Limit (mating with cylinder

0.00098" (0.025 mm)
head)
Cylinder Bore - Standard 3.8976" ± 0.0003" (99.0 mm ± 0.008 mm)

Cylinder
Cylinder Out of Round Limit 0.001" (0.025 mm)
Cylinder Taper Limit 0.001" (0.025 mm)
Cylinder to Piston Clearance 0.00019" - 0.00216" (.005 - .055 mm)
PISTON / RINGS / CONN ROD / CRANK / BALANCE

SHAFT INCHES (MM)
Piston - Standard O.D. 3.8957 - 3.8968″ (98.953 - 98.980 mm)
Piston Piston Pin Bore I.D. (Standard) 0.8662 - 0.8665″ (22.004 - 22.010 mm)
Piston Pin Bore I.D. (Service Limit) 0.8677" (22.042 mm)
Piston Pin O.D. (Standard) 0.8659" - 0.8661" (21.995 - 22.000 mm)

Piston Pin
Piston Pin O.D. (Service Limit) 0.8651" (21.975 mm)
Top Ring (Standard) 0.0059" - 0.0122" (0.15 - 0.31 mm)
Top Ring (Service Limit) 0.0137" (0.35 mm)
Second Ring (Standard) 0.0094" - 0.0196" (0.24 - 0.50 mm)

Installed Gap
Second Ring (Service Limit) 0.0220" (0.56 mm)
Oil Control Rails (Standard) 0.0098" - 0.0401" (0.25 - 1.02 mm)

Piston Ring
Oil Control Rails (Service Limit) 0.0480" (1.22 mm)
Top Ring (Standard) 0.0011" - 0.0037" (0.030 - 0.095 mm)
Top Ring (Service Limit) 0.0042" (0.108 mm)

Ring to Groove
Clearance Second Ring (Standard) 0.0007" - 0.0029" (0.020 - 0.076 mm)
Second Ring (Service Limit) 0.0035" (0.089 mm)
Connecting Rod Small End I.D. (Standard) 0.8665" - 0.8670" (22.010 - 22.023 mm)
Connecting Rod Connecting Rod Small End I.D. (Service Limit) 0.8682" (22.053 mm)
Connecting Rod Big End I.D. See Service Procedure Listed In This Chapter
Main Journal O.D. (Service Limit) 1.6137" (40.990 mm)

Crankshaft
Crankshaft Runout Limit (PTO and MAG) See Service Procedure Listed In This Chapter
Balance Shaft Bearing Journal O.D. (Standard) 1.1798 - 1.1802″ (29.969 - 29.979 mm)
ENGINE DETAIL
TORQUE VALUES / SEQUENCES / ASSEMBLY NOTES
ENGINE FASTENER TORQUE SPECIFICATIONS
570 Engine
Description Torque
Bearing Retainer Fastener 8 ft-lbs (11 Nm) Apply Loctite® 272™
Upper Cam Chain Guide Fasteners 7 ft-lb (10 Nm)
3
Cam Chain Tensioner 30 ft-lb (40 Nm)
Camshaft Carrier Bolts 8ft-lb (11 Nm)
Camshaft Sprocket Bolts 14 ft-lb (19 Nm)
Coolant Bleed Screw 72 in-lbs (8 Nm)
Coolant Temperature Sensor 17 ft-lb (23 Nm)
CPS Retaining Bolt 9 ft-lb (12 Nm)
Crankcase Bolts 22 ft-lbs (30 Nm)
Torque in Sequence Shown
Crankshaft Position Sensor (CPS) Fastener 9 ft-lbs (12 Nm)
Cylinder Head Bolts - Black Torque in sequence for all steps
Step 2: 26 ft-lb (35 Nm)
Torque The Outer M6 Head Bolts 89 ± 9 in-lbs (10
± 1 Nm)
Cylinder Head Bolts - Silver Apply light coat of engine oil to bolt threads and
under bolt head
Torque in Sequence for all steps
Step 3: Loosen all fasteners until they are
unseated
Torque The Outer M6 Head Bolts 89 ± 9 in-lbs (10
± 1 Nm)
ETC Fasteners 7 ft-lbs (10 Nm)
Engine Mount (front) 40 ft-lbs (54 Nm)
Engine Coupler (Rear) In Sequence:
55 ft-lb (75 Nm)
Exhaust Head Pipe Bolts 18 ft-lb (25 Nm)
IAC Mounting Screw 18 in-lbs (2 Nm)

Camshaft Sprocket Bolt 14 ft-lb (19 Nm)
Replace camshaft sprocket bolt if loosened or
removed.
Oil Gallery Plug: 11 ft-lbs (15 Nm)
Oil Filter Lubricate seal with engine oil. Turn by hand until
filter gasket contacts sealing surface, then turn an
additional 3/4 turn
Oil Pan Drain Plug 12 ft-lbs (16 Nm)
Oil Pickup 59.75 in-lbs (6.75 Nm )
Oil Pressure Regulator 20 ft-lbs (27 Nm)
Oil Pressure Regulator Valve Cover 8.8 ft-lbs (12 Nm)
Oil Pump Sprocket Bolt 9 ft-lbs (12 Nm)
Oil Pump Cover Bolt 8 ft-lbs (11 Nm)
Spark Plug 9 ft-lbs (12 Nm)
Do Not Apply Anti-seize
Starter Mounting Bolts 3 ft-lbs (4 Nm)
Starter One-Way Clutch Screws 9 ft-lbs (12 Nm)
Apply Loctite® 272™
Stator Cover Screws 9 ft-lb (12 Nm)
Stator Wire Routing Bolts 6 ft-lbs (9 Nm)
Thermostat Cover Bolts 8 ft-lbs (11 Nm)
T-MAP Retaining Bolt 24 in-lbs (2.8 Nm)
TPS Mounting Screws 18 in-lbs (2 Nm)
Valve Cover Bolts 9 ft-lbs (12 Nm)
Voltage Regulator Fasteners 75 in-lb (6 Nm)
Water Pump Cover Bolts 9 ft-lbs (12 Nm)
(Apply Loctite® 204™ to bolt threads)
Water Pump Impeller Finger Tight *LH threads
TORQUE SEQUENCE
CRANKCASE / TIMING CHAIN GUIDES / OIL PICKUP / REGULATOR VALVE
CYLINDER / OIL FILTER / OIL PUMP / BREATHER
CAMSHAFTS / CYLINDER HEAD / FLYWHEEL / STATOR COVER - BLACK HEAD BOLTS

Apply a drop of Loctite 641 (Yellow) to the crankshaft taper before assembly. Loctite 603 (Green) can be used if 641
is not available.
CAMS / CYL HEAD / FLYWHEEL / STATOR COVER - SILVER HEAD BOLTS
SPARK PLUG / STARTER / THROTTLE BODY / VALVE COVER
TORQUE
Spark Plug:
IMPORTANT
Fuel injector O-rings should be replaced if a fuel injector is removed or replaced.
Refer to the electronic parts catalog for the latest part number.
PISTON / CRANKSHAFT / BALANCE SHAFT
ENGINE COOLING SYSTEM

COOLING SYSTEM ASSEMBLY VIEW AND COOLANT FLOW DIAGRAM

q Radiator
w Fan Shroud
e Cooling Fan
r Recovery Bottle
t Radiator Drain Plug
y Upper Radiator Hose
u Lower Radiator Hose
i Bypass Hose
o Water Pump Hose
COOLING SYSTEM SPECIFICATIONS COOLING SYSTEM PRESSURE TEST

1. Remove the hood from the front cab.
COOLANT
CONDITION TEMPERATURE °F (°C) WARNING
Room Temperature 68° F (20° C) Never remove pressure cap when engine is warm or
hot. The cooling system is under pressure and serious
Thermostat Open 180° F (82° C) burns may result. Allow the engine to cool before
servicing.
Fan Off 192° F (89° C)
Fan On 198° F (92° C) 2. Remove pressure cap and pressure test the cooling
Thermostat Full Open Lift 203° F (95° C)

system using a commercially available pressure 3
tester.
Engine Temperature 233° F (112° C)
Overheat Indicator
Engine Protection
236° F (113° C)
Ignition Misfire
Engine Protection 257° F (125° C)
Shutdown
ITEM SPECIFICATION
Cooling 570 3.5 qts. (3.3 L)
System
Capacity 570 Crew 5.0 qts. (4.7 L)
Pressure Cap Relief 13 PSI

3. The system must maintain 10 psi for five minutes or
longer. If pressure loss is evident within five minutes,
Polaris Premium Antifreeze: check the filler neck, radiator, hoses, clamps and
2871534 - Quart water pump weep hole for leakage.
2871323 - Gallon
Recommended Coolant
Use only high quality antifreeze/coolant mixed with
distilled water in a 50/50 ratio, depending on freeze
protection required in your area.
CAUTION: Using tap water in the cooling system will
lead to a buildup of deposits which may restrict coolant
flow and reduce heat dissipation, resulting in possible
engine damage. Polaris Premium 50/50 Antifreeze/
Coolant is recommended for use in all cooling systems
and comes pre-mixed, ready to use.
PRESSURE CAP TEST RADIATOR

1. Open the hood (see “WARNING” under “Cooling 1. Check radiator air passages for restrictions or
System Pressure Test”). damage.
2. Remove pressure cap q and test using a pressure
cap tester (commercially available).

3. The pressure cap relief pressure is 13 psi. Replace pressure water.
cap if it does not meet this specification.
CAUTION
damage the radiator fins and impair the radiators
effectiveness. Use of a high-pressure washer is not
recommended.
COOLANT DRAIN / RADIATOR REMOVAL 9. Remove the two upper radiator retaining bolts e.
Coolant Drain
1. Open the hood.
WARNING
Never drain the coolant when the engine and radiator
are warm or hot. Hot coolant can cause severe burns.
Allow engine and radiator to cool.
2. Slowly remove the pressure cap to relieve any

cooling system pressure.
3
3. Place a suitable drain pan underneath the drain
valve on the front left side of the vehicle.
4. Drain the coolant from the radiator by opening the
drain valve q in the lower left corner of the radiator. 10. Disconnect the fan motor and remove the radiator
Properly dispose of the coolant. from the vehicle. Take care not to damage the
cooling fins.
11. Reverse procedure for installation.
5. Allow coolant to completely drain.

6. Place a suitable drain pan underneath the lower
engine hose w on the right rear side of the vehicle.
7. Remove the hose and completely drain the engine.

Radiator Removal
8. Remove the upper engine outlet hose and recovery
hose from the top of the radiator.
THERMOSTAT REPLACEMENT COOLING SYSTEM BLEEDING

1. Open the hood. PROCEDURE
WARNING WARNING
Allow the engine to cool before servicing. The cooling Always wear safety glasses and proper shop clothing
system is under pressure and serious burns may result. when performing the procedures in this manual. Failing
to do so may lead to possible injury or death.
2. Remove the pressure cap to relieve any system
pressure (see “Pressure Cap Test”).
CAUTION
3. Drain coolant to a level below the thermostat
housing. Use caution when performing these procedures.
Coolant may be hot and may cause severe injury or
4. Tilt the cargo box. burns.
5. Remove the two bolts q retaining the thermostat
cover. NOTE
If the coolant level is LOW in the radiator, or if there are
leaks in the system, the coolant system will not draw
coolant from the reservoir tank. It may be necessary to
safely raise the front of the vehicle 12” (30 cm) to bleed
the cooling system.
1. Allow engine and cooling system to completely cool.
CAUTION
Be sure the engine has cooled and no pressure is built
up in the cooling system before removing the pressure
cap. The coolant may be hot and could cause severe
injury or burns.
6. Lift the cover from the engine and remove the 2. Open the hood.
thermostat. 3. Remove the recovery bottle cap (Item 1) and fill the
7. Reverse this procedure for installation. Replace bottle to the MAX line.
thermostat seal if worn or damaged. Torque
thermostat cover bolts to specification.
TORQUE
Thermostat Cover Bolts:
8 ft-lbs (11 Nm)
8. Be sure to properly fill and bleed cooling system as

4. Remove the pressure cap (Item 2) and add the

necessary amount of Polaris Premium Antifreeze to
the radiator filler neck.
5. Remove the cargo box access cover to gain access
to the coolant bleed screw that is on top of the
thermostat housing.
6. Open the bleed screw (Item 3) to allow any trapped WATER PUMP COVER AND IMPELLER
air to escape. SERVICE (STATOR COVER REMAINS ON
ENGINE)
NOTE
The water pump cover, gasket and impeller can be
serviced with the stator cover installed on the engine.
CAUTION 3
injury or burns.
7. Fill the radiator until a steady stream of coolant 2. Disconnect the (-) negative battery cable.
begins to drain out of the bleed screw.
3. Remove all debris and thoroughly clean water pump
8. Tighten the bleed screw to specification, top off area and right-hand side of engine block.
coolant and properly install the pressure cap.
4. Open the hood.
TORQUE 5. Remove the pressure cap from the filler neck.
Coolant Bleed Screw:
6. Completely drain cooling system and engine as
72 in-lbs (8 Nm)
9. Start the engine and allow it to idle until the coolant 7. Raise and safely support the vehicle. Remove the
fan has cycled. right rear wheel.
10. Allow engine and cooling system to completely cool 8. Remove the eight bolts q attaching the water pump
down (see CAUTION). cover to the stator cover.
11. Remove the pressure cap. Add the necessary 9. Remove the water pump cover w and water pump
amount of Polaris Premium Antifreeze to the radiator cover gasket e. Discard the water pump gasket e.
filler neck. 10. Using an 8mm socket, remove the water pump
12. Open the bleed screw to allow any trapped air to impeller r.
escape. Close the bleed screw once a steady stream
of coolant begins to drain out. NOTE
13. Tighten the bleed screw to specification, top off The water pump impeller r uses reverse (left) threads.
coolant and properly install the pressure cap.
TORQUE
Coolant Bleed Screw:
72 in-lbs (8 Nm)
14. Fill the recovery bottle to the MAX line.

15. Reinstall the hood.
16. Reinstall cargo box access cover.
11. Inspect the water pump cover and impeller for

damage. Replace as necessary.
12. Follow this procedure in reverse to assemble the 7. Raise and safely support the vehicle. Remove the
water pump impeller and cover. Always use a new right rear wheel.
water pump cover gasket. Torque all fasteners in
8. Disconnect the stator wire connector and cut the tie
sequence to specification.
strap securing the wiring to the front engine mount
bracket.
TORQUE
9. Remove the CPS sensor from the stator cover on the
Water Pump Cover Fastener: right-hand side of the engine. Inspect CPS O-ring
9 ft-lbs (12 Nm)(Apply Loctite® 204™ to bolt and replace if needed.
threads)
Water Pump Impeller:

Finger Tight *LH threads
13. Fill and bleed cooling system as outlined in this

chapter.
WATER PUMP MECHANICAL SEAL / OIL

SEAL REPLACEMENT
NOTE
The stator cover must be removed from the engine to
service the water pump drive shaft, oil seal, mechanical
seal and bearing.
10. Remove the eight bolts q retaining the water pump
cover to the stator cover.
CAUTION
injury or burns.
2. Disconnect the (-) negative battery cable.

3. Remove all debris and thoroughly clean water pump
area and right-hand side of engine block.
4. Open the hood.
5. Remove the pressure cap from the filler neck.
6. Completely drain cooling system and engine as 11. Remove the water pump cover w and water pump
outlined in this chapter. cover gasket e. Discard the water pump gasket.
12. Remove the water pump impeller r. 17. Bring the stator cover assembly to a clean work
bench.
NOTE
18. Using a brass drift, remove the water pump drive
The water pump impeller uses reverse (left) threads. shaft u. Be sure not to damage the threads. Inspect
shaft for wear or damage, replace if necessary.
13. Remove the oil dipstick t.
19. Extract the mechanical seal i and the oil seal o

14. Remove the 13 bolts y securing the stator cover to from the stator cover.
the engine.
15. If needed, install the stator cover removal handle tool
(PA-49317) to the water pump cover bolt holes to aid
in stator cover removal.
20. Press out the water pump drive shaft bearing a from
the stator cover. Discard bearing and replace with
new.
CAUTION
when removing the stator cover.
result.
CAUTION
Be sure engine coolant does not contaminate the
Water Pump Assembly
21. Thoroughly clean the stator cover. 25. Install the water pump drive shaft holding tool in kit
PU-50869. Hold the tool in position and flip the
22. Press in a new water pump drive shaft bearing a
assembly up-side-down so the special tool PU-
until it is fully seated in the cover.
50869 is supporting the assembly.
CAUTION
Be sure bearing is fully seated in cover or severe
engine damage may result.
23. Clean and de-grease the water pump drive shaft (H).
24. Press in the water pump drive shaft into the bearing
using PU-50869 Item #1.
26. Lubricate the new water pump oil seal with clean
engine oil.
27. Use the water pump oil seal installation tool in kit PU- 31. Align the water pump drive shaft blade as shown
50869 to fully install the new water pump oil seal s. below.
CAUTION 32. Apply a small amount of crankcase sealant to the

area indicated below g.
Be sure the oil seal is fully seated in cover or severe
engine damage may result.
28. Use the water pump mechanical seal installation tool

in kit PU-50869 to fully install the new water pump
mechanical seal d until it is fully seated in the cover.

h Crankshaft
j Driveshaft
29. Install a new stator cover gasket onto the engine. k Mechanical Seal
30. Align the water pump drive slot as shown below. l Impeller
33. If needed, install the stator cover removal handles

tool PA-49317 to the water cover bolt holes to aid in
stator cover installation.
34. While installing the stator cover to the engine, slightly 36. Measure the installed height of the new mechanical
rotate the water pump impeller to verify the seal as shown below. If not within specification,
crankshaft slot and the water pump drive shaft blade remove and discard the mechanical seal and
are properly engaged. Verify the stator cover is properly install new mechanical seal as outlined in
laying flat on the engine case. this chapter.
CAUTION
The flywheel contains powerful magnets. Use caution MEASUREMENT
when installing the stator cover. Mechanical Water Pump Seal Installed Height:
DO NOT place fingers between cover and crankcase at 0.280 - 0.287″ (7.2 +/- 0.1 mm)
any time during the removal and installation process or
injury could result.
37. Install the water pump impeller 1(. Finger Tight *LH
threads
CAUTION NOTE
If the water pump drive shaft blade and slot in the crank The water pump impeller 1( uses reverse (LH) threads.
shaft are not in alignment during the installation
process, severe engine damage may result.
35. Install and torque the stator cover fasteners in

sequence to specification.
38. Install a new water pump cover gasket.
TORQUE
Stator Cover and Water Pump Cover:
9 ft-lbs (12 Nm)(Apply Loctite® 204™ to bolt
threads)
39. Install the water pump cover to the stator cover.

Torque all fasteners in sequence to specification.
40. Install the oil dipstick.

41. Install the coolant hose to the water pump cover and
tighten hose clamp.
tie strap securing the wiring to the front engine mount
bracket.
43. Install the CPS sensor into the stator cover. Inspect
CPS O-ring and replace if needed.
44. Install the right-hand rear wheel and torque the
wheel nuts to specification. Safely lower vehicle.
TORQUE
Steel Wheel Nuts:
36 ft-lbs (49 Nm)
Aluminum Wheel Nuts:
30 ft-lbs + 90º (41 Nm + 90º)
45. Install both seats and the engine service panel.

46. Connect the (-) negative battery cable.
47. If the engine oil was contaminated during this service
procedure, perform an engine oil change as outlined
in Chapter 2. DO NOT run the engine until coolant
has been added to the cooling system.
48. Fill cooling system with recommend coolant and
bleed the system of air as outlined in this chapter.
49. Check for leaks.
ENGINE SERVICE
ACCESSIBLE ENGINE COMPONENTS ENGINE REMOVAL
with the engine installed: NOTE
• Camshaft Some engine repair procedures can be performed
• Camshaft Sprockets without removing the engine assembly from the vehicle.
• Cylinder Head and Gaskets Refer to “Accessible Engine Components” for further
• Cylinder and Gaskets information.
• Piston and Rings The use of an overhead or portable engine hoist is the
• Flywheel only recommended method for removing and installing
• Starter Motor / Idler Gear Asm the engine.
• Stator (Alternator) Have an assistant help guide the engine in and out of
• Thermostat the vehicle while using an engine hoist to prevent
• Valve Cover personal injury or damage to vehicle components.
• Water Pump
• Camshaft Timing Chain and Guides
• Crankshaft Seal (PTO) CAUTION
• Oil Pump / Oil Pump Sprocket or Chain Correct Drive Clutch Puller P/N PA-48595
The following components require engine removal for
service:
• Counterbalance Shaft and Bearings
• Crankshaft and Bearings
• Crankcase
• Oil Pressure Regulator
• Oil Pump Pickup Assembly
TOP-END SERVICE (ENGINE IN CHASSIS)

ALL of the top-end engine components can be serviced
while the engine is mounted in the chassis.
WARNING
Always wear safety glasses and proper shop clothing
when performing the procedures in this Service
Manual.
Failing to do so may lead to possible injury.
1. If vehicle was recently operated, allow it to cool down

before attempting to perform any work.
2. Thoroughly clean the engine and chassis.
3. Drain the engine oil and engine coolant prior to 11. Disconnect the ETC (Item 1), T-MAP sensor (Item 2),
engine removal (see Chapter 2). harness leads from the throttle body.
4. Remove the seat. 12. Disconnect the fuel injector harness lead from the
fuel injector.
5. Disconnect the (-) negative battery cable from the
battery. 13. Place a shop to beneath the fuel line quick connector
to catch any fuel. Disconnect the fuel line (Item 3)
6. Remove the rear cargo box as an assembly (see from the fuel rail by pressing in on the quick
Body / Frame Chapter). Remove the box tilt shock connector tabs.
lower mount pin and remove the box tilt shock from
the frame.
7. Loosen the clamps securing the intake duct to air
box rubber boot and the throttle body to the engine.
Disengage the assembly from the boots and place
off to the left side.
NOTE
Be sure dirt and debris do not enter the engine, air box
or throttle body. Use clean shop towels to plug engine
and air box intake holes.
8. Remove the outer clutch cover, driven clutch, drive

belt, drive clutch and inner clutch cover. (see PVT
System Chapter).
NOTE 14. Move fuel line to the left-hand side of the engine
compartment. Make note of line routing for
Be sure to use the correct Drive Clutch Puller (PA- installation.
15. Remove the spark plug wire from the engine.
9. Disconnect the stator wire connector and cut the tie 16. Remove (+) positive cable (Item 4) from the starter
strap securing the wiring to the front engine mount motor. If desired, remove the remaining starter motor
bracket. Replace tie strap for engine installation. bolt and remove the starter motor from the engine.
10. Remove the CPS sensor from the stator cover on the
right-hand side of the engine. Plug CPS hole with
clean shop towel. Inspect CPS O-ring and replace if
needed.
17. Remove (-) negative cable (Item 5) from the starter 25. With the help of an assistant and the engine hoist,
mounting nut. raise the engine vertically out of the vehicle frame.
NOTE
personal injury or damage to the vehicle components.
26. Install the engine stand adapter (PU-50824) onto the

engine PTO side mounting ears as shown below.
18. Disconnect the upper engine coolant hose, bypass

hose, T-MAP, and ECT harness connector.
19. Remove the two bolts securing the muffler to the
frame. Remove the (3) hex bolts securing the
exhaust head pipe to the engine. Maneuver the
exhaust assembly out of the mounting grommet and
remove the exhaust assembly as one.
20. Place a support between the main frame and
transmission case. Do not pinch any lines.
27. Select the proper engine stand sleeve adapter and
21. Use an overhead or portable engine hoist and install it onto the engine stand adapter.
suitable engine straps to secure the engine in its
current position. • Sleeve adapter for a 2” bore engine stand:
• (PU-50625)
22. Remove the (4) bolts and nuts (Item 8) securing the • Sleeve adapter for a 2.375” bore engine stand:
engine to the front motor mount bracket. • (PW-47054)
23. Remove the (8) bolts (Item 7) securing the coupler 28. Place engine onto the engine stand (PU- 50624) for
brackets to the engine and transmission. service.
24. Loosen the (2) bolts and nuts (Item 6) so the engine
mount bracket can be slightly tilted away from
engine.
ENGINE INSTALLATION 6. Install the Clutch Center Distance Tool (PU-50658 or

Use the following procedure to reinstall the engine PU-50658-A) onto the crankshaft and transmission
assembly. input shaft. The pictures below show a properly
installed tool (PU-50658).
1. Attach engine with suitable lifting straps to an
overhead or portable engine hoist.
2. Remove the engine stand adapter plate.
3. Use the overhead or portable engine hoist and
suitable engine straps to lower the engine into the
vehicle frame.
NOTE
3
personal injury or damage to vehicle components.
4. By hand, install the (4) front engine mount bolts and

nuts (Item 1). Do not tighten at this time.
5. Install the four engine to transmission coupler plates
(Item 2) and instal the (8) bolts and washers (Item 3).
Do not tighten fasteners at this time.
NOTE
Images for Reference only. The tool shown should only
be used to check center to center distance.
NOTE The location the tool rests on the shafts may vary.
DO NOT torque fasteners at this time.
PU-50658–A
1 2012 RZR 570
2011-14 RZR 900
2 2014-15 RZR XP 1000
2013 RANGER 900
2014-16 ACE
2015-18 ACE 570
2015-16 RGR ETX
3
2013–18 RZR 570
2014–18 RANGER 500/570
4 2014-18 RANGER 900/1000
HOLE YEAR VEHICLE DESCRIPTION 9. Torque the two front center isolator bolts (Item 4) to
2015-18 RZR 900 specification.
2016-18 RZR 1000
2016–18 ACE 900
TORQUE
Isolator Center Bolt:
40 ft-lbs (54 Nm)
4
7. In sequence, torque the (8) engine coupler bracket 10. Remove the lifting straps and overhead or portable
fasteners to specification. engine hoist and remove the support previously
installed under the transmission case during the
engine removal process.
11. Reposition the head pipe assembly in the chassis
and install new muffler and head pipe seals (Item 5).
Install the (3) head pipe bolts (Item 6) and torque to
specification.
TORQUE
Rear Engine Coupler Fastener (In Sequence):
In Sequence:55 ft-lb (75 Nm)
8. In a criss-cross pattern, torque the (4) front engine

mount fasteners to specification.
TORQUE
TORQUE
Exhaust Head Pipe Bolts:
Front Engine Mount Fasteners: 18 ft-lbs (25 Nm)
40 ft-lbs (54 Nm)
12. Install the (2) springs (Item 7) securing the muffler to
the head pipe.
13. Install the (3) coolant hoses onto the engine.
14. Install the throttle body and air box. Tighten the hose
clamps that secure the throttle body to the intake
duct, intake boot and air box.
15. Install the lower stater motor bolt through the lower 27. Install the rear bumper and cargo box assembly (See
starter motor mounting boss. Body / Frame chapter).
16. Instal the starter motor onto the engine. 28. Install the left-hand rear wheel and torque wheel nuts
to specification.
17. Install the starter motor and battery cables as
outlined in the Electrical Chapter. TORQUE
TORQUE Steel Wheel Nuts:
36 ft-lbs (49 Nm)
Starter Motor Fastener:
3 ft-lbs (4 Nm)
30 ft-lbs + 90º (41 Nm + 90º)
18. Connect the harness leads to the ETC (Item 8) and
3
T-MAP sensor (Item 9). Verify routing is correct. 29. Remove the pressure cap and fill the cooling system
through the filler neck with properly mixed anti-freeze
/ coolant.
30. If the engine oil was completely drained, add
approximately 2 quarts (1.9 L) of Polaris PS-4
Synthetic Engine Oil into the crankcase.
31. Install a new oil filter. Lubricate the seal with engine
oil prior to installation (see Maintenance chapter).
32. Connect the (-) negative battery cable to the battery.
33. Install the engine service panel and seats.
34. Follow the “Cooling System Bleeding Procedure” as
35. Start engine and check for any oil or coolant leaks.
36. Check the engine oil level (see Maintenance
19. Connect the fuel injector harness lead to the fuel
chapter).
injector.
37. Refer customer to “Engine Break-In Period” upon
20. Connect the fuel line to the fuel rail.
returning vehicle to customer.
21. Connect the ignition coil harness connector and
install the spark plug wire.
22. Install the CPS and mounting bolt into the stator
cover and torque to specification.
TORQUE
CPS Fastener:
9 ft-lbs (12 Nm)

tie strap to secure the wiring to the front engine
mount bracket.
24. Install the inner clutch cover (See PVT System
chapter).
25. Install the drive clutch, driven clutch, belt and outer
clutch cover as outlined in the PVT System chapter.
Be sure all hose and wire routing is correct. Torque
all fasteners to specification as outlined in the PVT
System chapter.
26. Install the intake baffle assembly. Secure the 3
clamps that attach the assembly to the crankcase
vent, air box lid and inner clutch cover.
ENGINE BREAK-IN PERIOD ENGINE LUBRICATION SPECIFICATIONS

The break-in period consists of the first 25 hours of
operation, or the time it takes to use 15 gallons (57 liters) FLUID CAPACITY
of fuel. Careful treatment of a new engine and drive Oil Capacity
components will result in more efficient performance and Approx. 2 Quarts (1.9 L)
longer life for these components.
Oil Filter Wrench
CAUTION PU-50105 or 2.5” (64 mm)
Use only Polaris PS-4 Synthetic Engine Oil.
Never substitute or mix oil brands. Oil Type
Serious engine damage and voiding of warranty can Polaris PS-4 Synthetic Engine Oil
result.
Do not operate at full throttle or high speeds for Oil Pressure
extended periods during the first three hours of use. Minimum Specification
Excessive heat can build up and cause damage to (using Polaris PS-4 at operating temperature)
close fitted engine parts. 10 PSI @ 1200 RPM (Minimum)
40 PSI @ 7000 RPM(Minimum)
1. Fill fuel tank with unleaded fuel which has a minimum
pump octane number of 87 = (R+ M)/2.
2. Refer to Chapter 2. Check oil level indicated on the
dipstick. Add oil if necessary.
3. Drive slowly at first to gradually bring engine up to
operating temperature.
4. Vary throttle positions. Do not operate at sustained
idle or sustained high speed.
5. Perform regular checks on fluid levels, controls and
all important bolt torques.
6. Change oil and oil filter after break-in period at 25
hours.
ENGINE MOUNTING AND TORQUE VALUES

q Bolt Torque to 55 ft-lbs (75 Nm)
w Bolt Torque to 40 ft-lbs (54 Nm)
e Nut Torque to 25 ft-lbs (34 Nm)
r Bolt Torque to 18 ft-lbs (25 Nm)
SETTING TDC (TOP-DEAD-CENTER) 2. With the valve cover and thermostat housing
There are three ways to ensure the piston is at TDC. removed, rotate the engine so the cam lobes are
Remove the outer clutch cover to access the drive clutch facing outward and the Cylinder Holding and
to aid in engine rotation (manually turn the drive clutch Camshaft Timing Plate can be installed into the slots
counter clockwise). of the camshafts as shown below. This will set TDC
of the compression stroke.
1. With the CPS sensor removed, rotate the engine
until the “V” marked on the flywheel is aligned with
the CPS mounting hole. This will set TDC, but not
necessarily TDC of the compression stroke. View
the timing marks on the camshaft sprockets to
ensure the engine is at TDC of the compression
stroke.
Camshaft Timing Plate

PU-50563
NOTE
gasket surface and the exhaust cam sprocket should
3. With the stator cover and flywheel removed, rotate

the engine and position the piston at TDC by aligning
the timing hole in crank case with a timing hole in the
crankshaft.
4. Insert a 1/4” drive socket extension through the

crankcase and into the crankshaft locating hole q.
This will set TDC, but not necessarily TDC of the
compression stroke. View the timing marks on the
cam shaft sprockets to ensure the engine is at TDC
of the compression stroke.
ENGINE DISASSEMBLY / INSPECTION - TOP END

VALVE COVER REMOVAL CAMSHAFT / CARRIER REMOVAL
NOTE NOTE
The valve cover, camshafts, cylinder head, cylinder and The camshafts can be removed with the engine
piston can be serviced with the engine installed in the installed in the chassis.
chassis.
1. Rotate the engine so the piston is at Top Dead
1. If needed, remove the spark plug wire from the Center (TDC) on the compression stroke.
engine.
2. Remove dirt and debris from valve cover area.
3. Remove the three valve cover shoulder bolts q and
isolators w using a T40 driver.
4. Carefully lift valve cover from the engine and remove
it out of the right-hand rear wheel well area.
NOTE
To verify TDC, see the
“SETTING TDC”, page section in this chapter.
2. Remove the hydraulic cam chain tensioner t from

the cylinder. Replace the sealing washer y upon
5. Replace isolators after each usew reassembly.
6. Replace Valve cover seal eif oil leaks are evident
7. Remove the spark plug r. Stuff spark plug hole with
a shop towel to prevent anything from falling into the
combustion chamber (if further engine disassembly
is required).
3. Remove the two bolts retaining the fixed cam chain 7. Lift upward on the intake camshaft while rotating it
guide u and remove the assembly from the engine. counter-clockwise. Walk the timing chain off of the
Inspect the guide for wear and replace if necessary. sprocket. Carefully remove the intake camshaft from
the engine.
4. Remove the remaining six bolts that retain the

camshaft carrier i and carefully lift the carrier off the 8. Remove the cam chain from the exhaust camshaft
camshafts. sprocket a and remove the exhaust camshaft from
the engine.
CAMSHAFT SPROCKET INSPECTION

NOTE
Camshaft sprocket removal is not necessary unless the
replacement of the sprockets is required.
Inspect cam sprocket teeth q for wear or damage.

Replace timing chain and sprockets as a set if worn or
damaged.
NOTE
The crankcase has a lower guide to prevent the chain
from falling off the crankshaft.
5. Attach a hook or other tool to the camshaft chain to

prevent it from dropping down into the engine.
6. Mark the intake o and exhaust a camshafts to
ensure proper assembly.
TORQUE
Camshaft Sprocket Bolt:
14 ft-lb (19 Nm)Replace camshaft sprocket bolt if
loosened or removed.
CAMSHAFT INSPECTION EXHAUST CAMSHAFT DECOMPRESSION

Inspect all main journals and cam lobes as described MECHANISM
below and compare to specifications. Replace camshafts
or cylinder head if worn beyond service limit or if any NOTE
surface is pitted or damaged. Removal of the decompression mechanism is not
1. Visually inspect each cam lobe for wear or damage. necessary unless replacement is required.
2. Measure the height of each cam lobe from the base 1. Thoroughly clean and inspect the decompression
circle to highest point on the lobe using a mechanism q located on the exhaust camshaft.
micrometer. Compare to specification.
2. Replace the decompression assembly if any
excessive wear or binding is evident.
NOTE
Replace camshafts if damaged or if any part is worn 3. Be sure the decompression mechanism functions
past the service limit. smoothly and easily returns under spring pressure to
the resting position against gravity.
MEASUREMENT
Camshaft Lobe Height:
Intake: 1.5704" ± 0.0038" (39.89 ± 0.097 mm)
Exhaust: 1.5405" ± 0.0038" (39.13 ± 0.097 mm)
CAM CHAIN AND GUIDE SERVICE CYLINDER HEAD REMOVAL

NOTE NOTE
The crankcase has a removable lower cam chain drive The cylinder head can be serviced with the engine
guide that prevents the chain from disengaging the installed in the chassis.
crankshaft during engine service. Do not rotate head assembly up side-down until the
The cam chain, cam chain guides and cam chain valve tappets have been removed.
tensioner can be replaced with the engine installed in
the vehicle. 1. Remove and discard the two outer M6 bolts q that
retain the cylinder head w and the cylinder.
1. If not already performed, remove the valve cover,
stator cover, flywheel, cam chain tensioner, cam 2. Loosen the four cylinder head bolts e evenly 1/8 3
carrier and camshafts as outlined in this chapter. turn (60 degrees) at a time until all are loose.
2. Remove the two fasteners q that secure the cam 3. Remove and discard the cylinder head bolts e.
chain guides w to the crankcase. Replace with new upon assembly.
3. Remove the fastener e that secure the lower cam 4. Tap cylinder head lightly with a soft faced hammer
chain guide r to the crankcase. until loose. Tap only in reinforced areas or on thick
parts of the cylinder head casting.
4. Inspect the cam chain guides and replace if
excessive wear is evident. 5. Remove the cylinder head w and head gasket r.
5. Upon installation, torque all fasteners to specification

and reassemble engine and vehicle as outlined in
this chapter.
TORQUE
Upper Cam Chain Guide Fasteners:
7 ft-lb (10 Nm)
CYLINDER HEAD DISASSEMBLY 3. Push down on the spring and remove the split
keepers q.
CAUTION
NOTE
their location in the cylinder head for assembly
purposes. It is important to install cylinder head
components back in the same location. Mark each
component or place them in an organized rack as you
remove them.
1. Remove the valve tappet q from the cylinder head.

4. Slowly release valve spring pressure and remove the
compressor adapter.
5. Remove the valve retainer w, valve spring e, valve
stem seal r and valve spring seat t. Discard the
valve seal.
NOTE
Replace valve seals whenever cylinder head is
disassembled. Hardened, cracked or worn seals will
cause excessive oil consumption.
6. Lift up the cylinder head and push the valve y out,

keeping it in order for reassembly in the same valve
guide.
2. Compress the valve spring by hand using valve 7. Repeat the previous steps to remove the remaining
spring compressor adapter. valves.
8. Clean the combustion chamber and head gasket
surface.
Valve Spring Compressor Adapter

PV-43513-A
CYLINDER HEAD IDENTIFICATION CRANKCASE IDENTIFICATION

Refer to the images below to aid in 2015 and Prior VS. Refer to the images below to aid in 2015 and Prior VS.
2016 To Current Crank Case Identification. 2016 To Current Crank Case Identification.
NOTE NOTE
2015 and Prior Cylinder Head q. 2015 and Prior Crankcases use q dowel in the main
crank case.
NOTE
NOTE
2016 to Current Cylinder Head w.
2016 to Current Crankcases use w dowels.
CYLINDER HEAD INSPECTION VALVE INSPECTION

Thoroughly clean cylinder head surface to remove all 1. Remove all carbon from valves with a soft wire wheel
traces of gasket material and carbon. or brush.
2. Check valve face for excessive runout, pitting, and
CAUTION
burnt spots.
Use care not to damage gasket sealing surface. All
gasket surfaces must be clean, dry and free of any oil 3. To check for bent valve stems, mount valve in “V”
or grease upon assembly. Clean sealing surfaces with blocks and measure with a dial indicator.
rubbing alcohol or electrical contact cleaner. Do not
touch sealing surfaces of the new head gasket.
CYLINDER HEAD WARP INSPECTION

1. Lay a straight edge q across the surface of the
cylinder head at several different points and measure
warp by inserting a feeler gauge between the straight
edge and the cylinder head surface. If warp exceeds
the service limit, replace the cylinder head.
4. Check the end of the valve stem for flaring, pitting,

wear or damage.
MEASUREMENT
Cylinder Head Warp Limit:
.0024" (0.06 mm)
5. Inspect split keeper groove for wear or flaring in the

keeper seat area.
NOTE
The valves can be re-faced or end ground, if necessary.
They must be replaced if extensively worn, burnt, bent
or damaged.
6. Measure diameter of valve stem with a micrometer in COMBUSTION CHAMBER CLEANING

three places, then rotate 90° and measure again
(take six measurements total). Compare to WARNING
specifications.
Wear eye protection during combustion chamber
cleaning.
1. Clean all accumulated carbon deposits from

combustion chambers and valve seat area q.
MEASUREMENT
Valve Stem Diameter:
Intake: 0.2155" - 0.2161" (5.475 - 5.490 mm)
Exhaust: 0.2147" - 0.2153" (5.455 - 5.470 mm)
7. Measure valve guide inside diameter at the top

middle and end of the guide using a small hole
gauge and a micrometer. Measure in two directions. NOTE
Carbon Clean Fuel Treatment (2871326) can be used
to help remove carbon deposits.
Do not use a metal scraper, a coarse wire brush or
abrasive cleaners to clean the cylinder head. Damage
may result.
2. Visually inspect cylinder head gasket surface and

combustion chamber for cracks or damage. Pay
close attention to the areas around spark plug and
valve seats.
MEASUREMENT
Valve Guide I.D.:
0.2165" - 0.2171" (5.500 - 5.515 mm)
8. Be sure to measure each guide and valve

combination individually.
NOTE
The valve guides cannot be replaced.
VALVE SEAT RECONDITIONING Renewing Valve Seats

Valve seat reconditioning should be performed by a 1. Install pilot into valve guide.
technician proficient in cylinder head reconditioning
techniques. Reconditioning techniques vary, so follow 2. Apply cutting oil to valve seat and cutter.
the instructions provided by the valve reconditioning 3. Place 46° cutter on the pilot and make a light cut.
equipment manufacturer. Do not grind seats more than
necessary to provide proper seat surface, width, and 4. Inspect the cut area of the seat:
contact point on valve face. • If the contact area is less than 75% of the
circumference of the seat, rotate the pilot 180° and
WARNING make another light cut.
Wear eye protection or a face shield during cylinder • If the cutter now contacts the uncut portion of the seat,
head disassembly and reassembly. check the pilot. Look for burrs, nicks, or runout. If the
pilot is bent it must be replaced.
• If the contact area of the cutter is in the same place,
Valve Seat Inspection the valve guide is distorted from improper installation.
Inspect valve seat in cylinder head for pitting, burnt • If the contact area of the initial cut is greater than 75%,
spots, roughness, and uneven surface. If any of the continue to cut the seat until all pits are removed and a
above conditions exist, the valve seat must be new seat surface is evident.
reconditioned. If the valve seat is cracked the cylinder
head must be replaced. NOTE
Valve seat width and point of contact on the valve face is Remove only the amount of material necessary to
very important for proper sealing. The valve must contact repair the seat surface.
the valve seat over the entire circumference of the seat,
and the seat must be the proper width all the way 5. To check the contact area of the seat on the valve
around. If the seat is uneven, compression leakage will face, apply a thin coating of Prussian Blue paste to
result. If the seat is too wide, seat pressure is reduced, the valve seat. If using an interference angle (46°)
causing carbon accumulation and possible compression apply black permanent marker to the entire valve
loss. If the seat is too narrow, heat transfer from valve to face (A).
seat is reduced. The valve may overheat and warp,
resulting in burnt valves.
6. Insert valve into guide and tap valve lightly into place
a few times.
7. Remove valve and check where the Prussian Blue Intake Seat Cutter Diameter:
indicates seat contact on the valve face. The valve 1.567 in. (39.80 mm)
seat should contact the middle of the valve face or
slightly above, and must be the proper width.
NOTE
When using an interference angle, the seat contact
point on the valve will be very narrow, and is a normal
condition. Look for an even and continuous contact
point all the way around the valve face (A).
3
MEASUREMENT
Valve Seat Width:
Intake:
Std.: .0393" (1.00 mm)
Service Limit: .0551" (1.4 mm)
Exhaust:
Std.: .0590” (1.50 mm)
Service Limit: .0758" (1.9 mm)
Valve Seat Angles
1 - 30°
• If the indicated seat contact is at the top edge of the 2 - 45°
valve face and contacts the margin area (B) it is too 3 - 60°
high on the valve face. Use the 30° cutter to lower the
valve seat. Exhaust Seat Cutter Diameter:
• If too low, use the 70° cutter to raise the seat. When 1.364 in. (34.65 mm)
contact area is centered on the valve face, measure
8. Clean all filings from the area with hot soapy water.
seat width.
Rinse and dry with compressed air.
• If the seat is too wide or uneven, use both top and
bottom cutters to narrow the seat. 9. Lubricate valve guides with clean engine oil and
• If the seat is too narrow, widen using the 45° cutter and apply oil or water based lapping compound to the
re-check contact point on the valve face and seat width face of the valve.
after each cut.
NOTE
Lapping is not required if an interference angle
reconditioning method is used.
10. Insert the valve into its respective guide and lap
using a lapping tool or a section of fuel line
connected to the valve stem.
11. Rotate the valve rapidly back and forth until the cut CYLINDER INSPECTION
sounds smooth. Lift the valve slightly off of the seat, 1. Remove all gasket material from the cylinder sealing
rotate 1/4 turn, and repeat the lapping process. Do surfaces.
this four to five times until the valve is fully seated,
and repeat process for the other valves. 2. Inspect the top of the cylinder for warpage using a
straight edge and feeler gauge.
12. Thoroughly clean cylinder head and valves.
CYLINDER REMOVAL
1. Remove and discard the head gasket.
2. Position the cam chain and guides vertically.
3. Tap cylinder lightly with a plastic hammer in the
reinforced areas only until loose.
4. Rock cylinder forward and backward and lift it from
the crankcase, supporting piston and connecting rod.
5. Remove the cylinder from the engine.
Cylinder Warpage:
.00098” (.025 mm)
3. Inspect cylinder for wear, scratches, or damage.

4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure in
two different directions, front to back and side to
side, on three different levels (1/2" down from top, in
the middle, and 1/2” up from bottom).
6. Remove and discard cylinder base gasket.
5. Record measurements taken in Step 4. If cylinder is PISTON-TO-CYLINDER CLEARANCE

tapered, or out of round beyond .001, cylinder must 1. Measure the outside diameter of the piston 12 mm
be re-bored oversize, or replaced. from the skirt and at a right angle to the direction of
Cylinder Taper Limit: the piston pin q.
.001″ Max. (0.025 mm)
Cylinder Out of Round Limit:
.001″ Max. (.025 mm)
Standard Bore Size:

3.8976 +/- 0.0003″ (99.0 +/- 0.008 mm) 3
PISTON REMOVAL
1. Note piston directional indicator “EX” positioned
toward the exhaust side of engine.
2. Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston
slightly with a heat gun. 2. Subtract this measurement from the maximum
cylinder size measurement from cylinder inspection.
CAUTION Piston to Cylinder Clearance:
Do not apply heat to the piston rings, they may lose .00177 - .002925″ (.045 - .075 mm)
radial tension. Piston O.D.:
3.8957 - 3.8968″ (98.953 - 98.980 mm)
3. Remove top ring.
*Using a piston ring pliers: Carefully expand ring
and lift it off the piston.
CAUTION
Do not expand the ring more than the amount
necessary to remove it from the piston.
*By hand: Using both thumbs, spread the ring open

and push up on the opposite side.
4. Repeat procedure for second ring.

5. Remove oil control ring top rail first, then bottom rail.
6. Remove oil control ring expander.
PISTON / ROD INSPECTION 3. Measure connecting rod small end ID. Inspect
1. Measure piston pin bore inside diameter I.D. bearing surface for damage.
Piston Pin Bore: Piston Pin Degree of Fit:

Std.: 0.8662 - 0.8665″ (22.004 - 22.010 mm) Pin should be a push-fit by hand with piston at room
temperature or warmed slightly
Service Limit: 0.8651″ (21.975 mm)
Connecting Rod Small End ID:
Std.: 0.8665 - 0.8670″ (22.010 - 22.023 mm)
2. Measure piston pin O. D. Replace piston and/or
piston pin if out of tolerance.
4. Measure piston ring to groove clearance by placing
the ring in the ring land and measuring with a
thickness gauge. Replace piston and rings if ring-to-
groove clearance exceeds service limits.
Piston Pin O.D.:

Std.: 0.8659 - 0.8661″ (21.995 - 22.0 mm)
Piston Ring-to-Groove Clearance
Top Ring:
Std.: 0.0011 - 0.0037" (0.030 - 0.095 mm)
Service Limit: 0.0042" (0.108 mm)
Second Ring:
Std.: 0.0007 - 0.0029" (.020 - 0.076 mm)
Service Limit: 0.0035" (0.89 mm)
PISTON RING INSTALLED GAP

1. Place each piston ring inside cylinder. Use a piston
to push the ring squarely into place 1” (25.4 mm)
down from the cylinder head gasket surface.
2. Measure installed gap with a feeler gauge at location HONING TO OVERSIZE

q.
CAUTION
If cylinder wear or damage is excessive, it will be
necessary to oversize the cylinder using a new
oversized piston and rings. This may be accomplished
by either boring the cylinder and then finish honing to
the final bore size, or by rough honing followed by finish
honing.
CAUTION 3
For oversize honing always wet hone using honing oil
and a coarse roughing stone. Measure piston (see
piston measurement) and calculate finished bore size.
Always leave .002 - .003" (.05 - .07 mm) for finish bore
sizing with a fine stone.
Piston Ring Installed Gap A finished cylinder should have a 45 degree cross-hatch
Top Ring: pattern to ensure piston ring seating, aid in oil retention
Std: 0.0059 - 0.0122" (0.15 - 0.31 mm) and reduce ring vibration during initial break-in. Hone
Limit: 0.0137" (0.35 mm) cylinder according to hone manufacturer’s instructions,
Second Ring: or these guidelines:
Std: 0.0094 - 0.0196" (0.24 - 0.50 mm)
• Use a motor speed of approximately 300-500 RPM,
Limit: 0.022" (0.56 mm) run the hone in and out of the cylinder rapidly until
Oil Ring Rails: cutting tension decreases. Remember to keep the
Std: 0.0098” - 0.0401" (0.25 - 1.02 mm) hone drive shaft centered (or cylinder centered on
Limit: 0.0480" (1.22 mm) arbor) and to bring the stone approximately 1/2" (1.3
cm) beyond the bore at the end of each stroke.
• Release the hone at regular intervals and inspect the
NOTE bore to determine if it has been cleared, and to check
Always check piston ring installed gap after re-boring a piston fit.
cylinder or when installing new rings.
NOTE
Do not allow cylinder to heat up during honing.
CYLINDER HONE SELECTION / HONING CAMSHAFT INSTALLATION / TIMING

PROCEDURE
NOTE
CAUTION If any valve train components were replaced, refer to
Selecting a hone which will straighten as well as “Valve Clearance Adjustment”, page 3.149
remove material from the cylinder is very important. procedure prior to “Camshaft Installation / Timing”.
Using a common spring loaded finger type glaze
breaker for honing is never advised. Polaris 1. Rotate the engine and position the piston at TDC.
recommends using a rigid hone or arbor honing
machine which also has the capability of oversizing. 2. Reference the intake q and exhaust w markings
made during disassembly.
Cylinders may be wet or dry honed depending upon the
hone manufacturer’s recommendations. Wet honing
removes more material faster and leaves a more distinct
pattern in the bore.
CLEANING THE CYLINDER AFTER HONING

It is very important that the cylinder be thoroughly
cleaned after honing to remove all grit material. Wash the
cylinder in a solvent, then in hot, soapy water. Pay close
attention to areas where the cylinder sleeve meets the
aluminum casting. Use electrical contact cleaner if
necessary to clean these areas. Rinse thoroughly, dry
with compressed air, and oil the bore immediately with
engine oil.
3. Lubricate all camshaft lobes and bearing journal
surfaces with Polaris PS-4 engine oil prior to
installation.
4. Place the exhaust cam into the cylinder head and
align the timing marks as shown below.
5. Wrap the cam chain around the exhaust cam

sprocket and hold the exhaust cam in its current
position.
6. Carefully install the intake cam at an angle to allow 8. Install the upper cam chain guide and the eight bolts
for cam chain installation. Roll the cam shaft into its that retain the camshaft carrier. Tighten the bolts
bearing pockets and verify that the timing marks are evenly until snug. Do not torque at this time.
in alignment as shown below.
9. Install the Cylinder Holding and Camshaft Timing

Plate into the end of camshafts as shown.
NOTE
Cylinder Holding / Camshaft Timing Plate:
gasket surface and the exhaust cam sprocket should PU-50563
7. Carefully install the camshaft carrier onto the

camshafts.
10. Verify cam timing is correct and the piston is a TDC. 14. Torque the camshaft carrier bolts in sequence to
specification.
NOTE
For correct sprocket orientation, insure the “I” for intake
on cam and the “E” for exhaust on cam are positioned
as shown. View from mag side.
TORQUE
7 ft-lbs (10 Nm)
11. If timing marks are not aligned: 15. Insure the new sealing washer u is in place.
• Remove the Camshaft Timing Plate from the end of 16. Install the hydraulic cam chain tensioner i into the
the camshafts. cylinder and torque to specification.
• Remove the cam carrier bolt and cam carrier.
• Correct the camshaft timing as needed.
• Reinstall the cam carrier.
• Re-check cam timing.
12. Remove the Cylinder Holding & Camshaft Timing
Plate from the end of the camshafts.
PU-50563
13. If needed, install the camshaft carrier and bolts.
TORQUE
Cam Chain Tensioner:
30 ft-lb (40 Nm)
17. Rotate crankshaft through two revolutions and verify

camshaft timing is correct.
CAMSHAFT TIMING - QUICK REFERENCE

Rotate engine so the cam lobes are facing outward and Intake cam sprocket should have “I” marks aligned with
the Cylinder Holding and Camshaft Holding Plate can be gasket surface and the exhaust cam sprocket should
installed into the slots of the camshafts as shown. have “E” marks aligned with gasket surface.
Stator Cover/Flywheel Removed. Flywheel Key faces Stator Cover/Flywheel Installed. “V” marked on the
down and insert a 1/4” drive socket extension through flywheel is aligned with the CPS mounting hole.
the crankcase and into the crankshaft locating hole q.
ENGINE ASSEMBLY - TOP END

PISTON RING INSTALLATION 3. Install upper ring with end gap positioned as shown.
NOTE
Apply clean engine oil to all ring surfaces and ring lands
upon installation. Always check piston ring installed gap
before rings are installed on piston (see Chapter 3 –
Piston Ring Installed Gap, page 3.136). Clean
accumulated carbon from piston ring grooves and oil
ring lube holes if piston has been in service.
REF DESCRIPTION
y Upper Ring Gap Position
u Lower Ring Gap Position

Spring Expander Gap Position
i (PTO Side)
4. Install second ring with marking facing top of piston.

REF DESCRIPTION Rotate ring to position the end gap toward intake
side of piston as shown below.
q Top Ring (Marking up)
5. Install top ring with mark facing top of piston. Rotate
w Second Ring (Marking up) ring to position the end gap toward exhaust side of
piston as shown below.
e Upper Rail
r Spring Expander
t Lower Rail
1. Place oil control ring expander in oil ring groove.

Rotate expander in groove until butt ends are on
PTO side of piston (see illustration 1).
NOTE
Ends must butt squarely together and must not overlap.
2. Install lower ring with end gap positioned as shown in

Step 3.
REF DEFINITION
o Second Ring Gap Position
a Top Ring Gap Position
6. Be sure top and second rings rotate freely in their

grooves and do not bind when compressed by hand.
PISTON / CONNECTING ROD ASSEMBLY CAUTION

1. Lubricate connecting rod small end, piston pin bore DO NOT apply heat to piston rings or a loss of
and piston pin with engine oil. radial tension could result.
CAUTION
Do not re-use circlips. Circlips become deformed during
the removal process.
Do not compress the new clip more than necessary to
prevent loss of radial tension. Severe engine damage
may result if circlips are re-used or deformed during
installation. 3
2. Install a new circlip on one side of piston with gap at
the top (12:00 position) or bottom (6:00 position).
NOTE
Never re-use a piston pin circlip.
3. When installing the piston, be sure the piston

marking “EX” is positioned towards the exhaust side 5. Install the remaining circlip r with gap at the top
of the engine. (12:00 position) or bottom (6:00 position). Push the
piston pin in both directions to make sure the clips
are properly seated in the groove.
4. Place piston q on connecting rod w. Push piston pin

e through rod and piston until it seats against the
installed circlip.
NOTE
Do not tap on pin or cause any sideways force to
connecting rod. Warm piston crown with a heat gun if
pin cannot be installed by hand, or use a piston pin
installation tool.
CYLINDER INSTALLATION 9. Hold the cylinder in place and rotate the engine and
1. Clean base gasket sealing surface on cylinder and position the piston at TDC.
crankcase to remove all oil, grease, or old sealant.
NOTE
2. Install a new base gasket. If cam chain and flywheel are installed (top end work
only is being performed) hold cam chain tight while
NOTE
rotating the engine to avoid damage to the chain, drive
Base gasket and surfaces must be DRY and oil free. sprocket teeth, or tensioner blade.
Use care upon assembly to keep oil away.
3. Slide a commercially available Piston Support Block CYLINDER HEAD ASSEMBLY

under piston skirt to support piston during cylinder
installation. NOTE
Assemble the valves one at a time to maintain proper
order.
WARNING
1. Apply engine oil to valve guides and seats.

2. Lubricate the valve stems with clean engine oil.
3. Install the valve q in the cylinder head, through the
guide.
4. Apply clean engine oil to cylinder bore and bottom

tapered portion of cylinder sleeve.
5. Verify all ring end gaps are correctly located on
piston. Place cam chain and guides in alignment with
chain room.
6. Carefully compress rings with fingers or
commercially available spring compression tool and
install cylinder with a slight front to back rocking
motion until all rings are captive in cylinder and past
the taper of the sleeve.
7. Remove support block and ring compressor.
8. Push cylinder downward until fully seated on base
gasket.
4. Carefully install a new valve seal w on the valve
guide with a rotating motion. Push firmly until seated
in retaining groove and square with the guide
5. Dip the seat e, valve spring r and retainer t in
clean engine oil.
6. Install the valve spring seat e.
7. Install the valve spring r with tightly spaced coils 13. Install the valve tappet i for each valve in the order
facing down toward the cylinder head. they were removed.
NOTE NOTE
Valve springs to be installed with the paint mark facing If any valve train components were replaced, refer to
up. “Valve Clearance Adjustment”, page 3.149
procedure prior to “Camshaft Installation / Timing”
8. Place the valve retainer t on the spring. procedure.
9. Compress the valve spring by hand using valve
spring compressor adapter. Compress spring only
enough to allow split keeper installation. VALVE SEALING TEST
1. Clean and dry the combustion chamber area q.
2. Pour a small amount of clean solvent into each
intake port w and check for leakage around the
valves. The valve seats should hold fluid with no
seepage.
3. Repeat for exhaust valves by pouring fluid into each
exhaust port e.
Valve Spring Compressor Adapter

PV-43513-A
NOTE
To prevent damage to the valve seals, do not compress
the valve spring more than necessary to install the
keepers.
10. Install split keepers y with gap even on both sides.

11. Repeat this procedure for remaining valves.
12. Exercise each valve through its travel to ensure the
valve keepers are seated correctly.
CYLINDER HEAD IDENTIFICATION CRANKCASE IDENTIFICATION

Refer to the images below to aid in 2015 and Prior VS. Refer to the images below to aid in 2015 and Prior VS.
2016 To Current Crank Case Identification. 2016 To Current Crank Case Identification.
NOTE NOTE
2015 and Prior Cylinder Head q. 2015 and Prior Crankcases use q dowel in the main
crank case.
NOTE
NOTE
2016 to Current Cylinder Head w.
2016 to Current Crankcases use w dowels.
CYLINDER HEAD INSTALLATION - BLACK 5. Install and finger tighten the four new cylinder head
BOLTS bolts u evenly.
6. Install and finger tighten the two new outer M6 bolts
NOTE
i evenly.
Use care during assembly to keep oil and finger prints 7. Torque the new cylinder head bolts in sequence to
off of gasket. specification.
TORQUE
1. Verify the cylinder head bolts are BLACK. If
uncertain, measured bolts in the reduced diameter Cylinder Head Bolts:
portion of the bolt shank (between A and B); verify Torque in sequence for all steps 3
the are the correct color and diameter before Step 1: 21 ft-lbs (28 Nm)
proceeding.
Step 2: 26 ft-lb (35 Nm)
MEASUREMENT Step 3: Additional 135°
Diameter Between A - B: Torque The Outer M6 Head Bolts 89 ± 9 in-lbs
(10 ± 1 Nm)
q Black: 9.00 +/- .1 mm
w Silver: 8.20 +/- .1 mm
CAUTION
Torquing cylinder head bolts using the incorrect
procedure may lead to engine component damage.
2. Prepare cylinder head gasket sealing surfaces by

cleaning thoroughly to remove all residue. The new
head gasket must be installed clean and dry, free
from oil or grease.
NOTE
Do not touch sealing surfaces of the new head gasket.
3. Guide cam chain r through a new head gasket t

and install the gasket on the cylinder, locating it on
the alignment pins.
4. Carefully set the cylinder head y in place on
alignment pins.
NOTE
Install new cylinder head bolts.
CYLINDER HEAD INSTALLATION - SILVER CAUTION

BOLTS Torquing cylinder head bolts using the incorrect
procedure may lead to engine component damage.
NOTE
Use care during assembly to keep oil and finger prints 2. Prepare cylinder head gasket sealing surfaces by
off of gasket. cleaning thoroughly to remove all residue. The new
head gasket must be installed clean and dry, free
from oil or grease.
1. Verify the cylinder head bolts are SILVER. If
uncertain, measured bolts in the reduced diameter NOTE
portion of the Cylinder head bolt shank (between A Do not touch sealing surfaces of the new head gasket.
and B); verify the are the correct color and diameter
before proceeding.
3. Guide cam chain r through a new head gasket t
MEASUREMENT and install the gasket on the cylinder, locating it on
the alignment pins.
Diameter Between A - B:
4. Carefully set the cylinder head y in place on
q Black: 9.00 +/- .1 mm alignment pins.
w Silver: 8.20 +/- .1 mm
NOTE
Install new cylinder head bolts.
5. Install and finger tighten the four new cylinder head

bolts u evenly.
6. Install and finger tighten the two new outer M6 bolts
i evenly.
7. Torque the new cylinder head bolts in sequence to
specification.
TORQUE VALVE CLEARANCE CHECK /

Cylinder Head Bolts: ADJUSTMENT
Apply light coat of engine oil to bolt threads NOTE
and under bolt head
Always inspect valve clearance prior to camshaft
Torque in Sequence for all steps installation or final engine assembly.
Step 2: 30 ft-lbs (40 Nm) 1. Install the cam chain guides and cam chain before
Step 3: Loosen all fasteners until they are camshaft installation (if removed) as outlined in this
unseated chapter.
Step 4: 15 ft-lbs (20 Nm) 2. Reference the camshaft intake q and exhaust w 3
Step 5: 26 ft-lbs (35 Nm) markings made during disassembly. If installing new
camshafts or if camshafts were not marked, you can
reference the part number stamped on the end of the
Step 7: Additional 180° shafts.
Torque The Outer M6 Head Bolts 89 ± 9 in-lbs
(10 ± 1 Nm)
3. Lubricate the camshaft bearing journal surfaces with

Polaris PS-4 engine oil prior to installation.
4. Carefully install the camshafts into the cylinder head.
The camshaft lobes should face out.
5. Carefully install the camshaft carrier onto the

camshafts.
6. Install the upper cam chain guide and the eight bolts 8. Install the Cylinder Holding and Camshaft Timing
that retain the camshaft carrier. Plate into the end of camshafts as shown below. The
thermostat housing must be removed to install the
timing plate PU-50563.
7. Torque the camshaft carrier bolts in sequence to

specification.
PU-50563
9. Measure the valve clearance of each valve using a

thickness (feeler) gauge. Record the measurement if
clearance is out of specification.
MEASUREMENT
Intake Valve Clearance (cold):
.006 ± .002″ (0.150 ± .050 mm)
MEASUREMENT
Exhaust Valve Clearance (cold):
.008 ± .002″ (0.200 ± .050 mm)
TORQUE
Camshaft Carrier Bolts: 10. If any of the valve clearance measurements are out
7 ft-lbs (10 Nm) of specification, remove the camshaft carrier and
camshafts and proceed with this procedure.
NOTE
If all valve clearance measurements are within
specification, remove the camshaft carriers and
proceed to “Camshaft Installation / Timing”.
11. Remove the valve tappet q from a valve that was

out of specification.
NOTE
their location in the cylinder head for assembly
purposes. Mark each component or place them in an
organized rack as you remove them.
12. Record the 3-digit number engraved on top of the

tappet.
13. Reference the valve clearance measurement
recorded for that valve, along with the 3-digit tappet
number.
14. Refer to the appropriate tappet selection matrix
(Intake or Exhaust) on the following pages and select
the proper tappet.
15. Install the new tappet.
NOTE
Lubricate the outer portion of the valve bucket upon
installation.
16. Repeat steps until all necessary valves have been

adjusted.
17. Reinstall the camshafts and camshaft carriers and
tighten the bolts evenly to specification.
TORQUE
7 ft-lbs (10 Nm)
18. Measure and confirm that valve clearance is now

within specification for each valve.
19. If valve clearance is not within specification, repeat
this procedure.
20. If all valve clearance measurements are now within
specification, remove the camshaft carriers and
proceed to “Camshaft Installation / Timing”.
VALVE LASH - TAPPET SELECTION

A 440 tappet means the thickness of the tappet is 4.40 mm. Part Number: 5138477-XXX (X’s represent 3 digit tappet
size)
An Engine Valve Lash Adjustment calculator has been created and is located under Service and Warranty – News,
Forms and Links. Click or go to
https://www.polarisdealers.com/files/ServWarr/English/Engine%20Valve%20Adjustment%20Calculator.pdf
The proper valve tappet may also be obtained by completing these steps:
IMPORTANT
The Valve Lash Specification and Measured Valve lash must be calculated in millimeters (mm)
1. Subtract the actual valve lash on the engine from the valve lash specification (i.e. 0.29 mm – 0.20 mm) = 0.09 mm.
2. Divide the 3 digit tappet number by 100 (i.e. 450 / 100) = 4.5 mm.
3. Add the results of step 1 and step 2 (i.e. 0.09 mm + 4.5 mm) = 4.59 mm.
4. Multiply that answer by 100 to obtain the correct new tappet (i.e. 4.59 mm x 100 = 459).
5. Refer to the table below to find the closest available tappet size to the result from step 4 (i. e. 459 should be
rounded to 460 since there is a 460 tappet).
Available Tappets
440 450 460 470 480 490 500 510 520 530 540
442 452 462 472 482 492 502 512 522 532 542
445 455 465 475 485 495 505 515 525 535 545
448 458 468 478 488 498 508 518 528 538
EXHAUST VALVE LASH - TAPPET SELECTION MATRIX

Tappet Thickness Example: 440 equals thickness of MEASUREMENT
4.40 mm. Part Number: 5138477-XXX (X’s represent 3
digits on tappet) Exhaust Valve Clearance (cold):
.008 ± .002″ (0.200 ± .50 mm)

440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525

0.000-0.024 420 422 425 428 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505
0.025-0.049 422 425 428 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508
3
0.050-0.074 425 428 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510
0.075-0.099 428 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512
0.100-0.124 430 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515
0.125-0.149 432 435 438 440 442 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518
0.150–0.250
(standard)
0.251–0.275 445 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530
Exhaust Valve Clearance Before Adjusting (mm)
0.276–0.300 448 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532
0.301–0.325 450 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535
0.326–0.350 452 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538
0.351-0.375 455 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540
0.376-0.400 458 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542
0.401-0.425 460 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.426-0.450 462 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.451-0.475 465 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.476-0.500 468 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.501-0.525 470 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.526-0.550 472 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.551-0.575 475 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.576-0.600 478 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.601-0.625 480 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.626-0.650 482 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.651-0.675 485 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.676-0.700 488 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.701-0.725 490 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.726-0.750 492 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.751-0.775 495 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.776-0.800 498 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.801-0.825 500 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.826-0.850 502 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.851-0.875 505 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.876-0.900 508 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.901-0.925 510 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.926-0.950 512 515 518 520 522 525 528 530 532 535 538 540 542 545
0.951-0.975 515 518 520 522 525 528 530 532 535 538 540 542 545
0.976-1.000 518 520 522 525 528 530 532 535 538 540 542 545
VALVE COVER INSTALLATION

1. Install the spark plug q and torque to specification.
TORQUE
Spark Plug:
2. Prepare valve cover sealing surfaces by cleaning

thoroughly to remove all residue.
3. Apply a small amount of crankcase sealant to the
cylinder head half-moon cutouts t as shown.
Crankcase Sealant: 2871557
4. Install a new valve cover seal w.

5. Install the three valve cover shoulder bolts e and
new isolators r Around each T40 fastener.
6. Torque valve cover bolts to specification.

TORQUE
Valve Cover Bolts:
7 ft-lbs (10 Nm)
ENGINE DISASSEMBLY / INSPECTION - LOWER END

CRANKCASE DISASSEMBLY 6. Hold flywheel special service tool and remove
flywheel nut and washer e. Discard the flywheel nut
NOTE and replace for assembly.
The engine top end, starter motor, stator cover, starter Flywheel special service tool:
drive, flywheel, stator, cam chain, oil pump and PU-51220
sprockets can be serviced with the engine installed in
the vehicle.
NOTE
STATOR COVER REMOVAL

The flywheel nut has standard rotation (right hand) 3
threads.
bolts (See “Engine to Transmission Coupler 7. Back the center screw of flywheel puller completely
Service”). out and screw puller onto flywheel completely.
CAUTION
when removing the stator cover.
result.
2. Disconnect stator harness connector.

3. Disconnect CPS connector.
4. Remove stator cover fasteners.
5. Remove starter drive gear w and shaft q. Inspect
gear teeth for damage. Inspect fit of shaft inside gear
and replace gear assembly if clearance is excessive.
Inspect shaft and shaft bearing surfaces in case and Flywheel puller:
stator housing for wear. PA-49316
8. Tighten center bolt of the flywheel puller and remove

flywheel.
STARTER ONE-WAY CLUTCH INSPECTION

1. Remove flywheel as outlined in this chapter.
2. Place flywheel on work bench. Grasp gear and rotate
clockwise. It should turn smoothly without binding.
3. Rotate gear counterclockwise. The gear should
immediately lock in position and not slip.
4. Inspect inside of hub q for wear, galling, or uneven 7. Remove the three, one-way clutch retaining bolts.
surface.
8. Remove clutch and inspect both sides of drive rollers

5. Inspect crankshaft bearing surface for abnormal
wear.
w and roller contact surface e inside hub for wear,
damage, or uneven surface.
6. Remove starter gear from the flywheel assembly.

9. Inspect drive surface of starter gear r and bearing
surface t for wear, damage, or uneven surface. If
any starter clutch component is worn or damaged,
replace clutch, clutch hub, and starter gear.
STATOR REMOVAL
NOTE
Test stator wire continuity before removing it from the
housing.
1. Remove the stator cover.
CAUTION
when removing the stator cover. 3
result.
CAUTION
Be sure engine coolant does not contaminate the
3. Remove the three bolts e that secure the stator q

to the stator cover w.
4. Remove the two bolts that secure the stator wire

routing bracket r to the stator cover.
5. Remove the stator q from the stator cover.
OIL PUMP REMOVAL
REF DESCRPITION NOTES

q Screw
w Cover, Oil Pump
e Washer
r Pin, Solid
t Shaft, Oil Pump
y ASM., Gerotor
1. Remove the stator cover (Refer to “Stator Cover 4. Remove the upper oil pump sprocket spacer.
Removal”, page 3.155)
2. Remove the two oil pump sprocket bolts and
washers. Discard the bolts and replace with new for
assembly. Remove the sprockets and chain from the
engine.
5. Remove the three bolts securing the oil pump cover

to the crankcase.
6. Grasp the oil pump shaft and pull it outward to
remove the shaft, oil pump cover and inner oil pump
geroter. This will prevent the oil pump drive pin from
3. Inspect the oil pump chain for worn or missing rollers falling out and into the crankcase.
or damage. Chain should be replaced as a set with
sprockets if sprocket teeth are worn.
NOTE
The gerotor set has two orientation dots that must be
NOTE installed inward upon assembly
The larger oil pump sprocket s mounts to the balance (Figure 1 on the next page).
shaft extension, the smaller oil pump sprocket d
mounts to the oil pump shaft. 7. Remove the center geroter, pin and shaft from the oil
pump cover.
NOTE
There is a spacer f in between the inner oil pump
geroter and the oil pump cover.
8. Remove the oil pump geroter that is in the engine

case (if needed).
9. Clean the geroters to remove oil.
10. Inspect surfaces of pump cavity in crankcase and 6. Install the oil pump cover r onto the shaft assembly.
surface of pump cover for scoring or wear.
7. Grasp the complete oil pump assembly by the drive

11. Inspect gerotor for scoring or other damage. Replace shaft and install the assembly into the crankcase.
parts as a set if damaged.
8. Install the three oil pump cover bolts and torque to
specification.
9. Torque cover bolts to specification.
TORQUE
Oil Pump Cover Bolts:
8 ft-lbs (11 Nm)
FLUID CAPACITY
Oil Capacity
Approx. 2 Quarts (1.9 L)
Oil Filter Wrench

PU-50105 or 2.5” (64 mm)
OIL PUMP ASSEMBLY Oil Type

1. Clean and dry all parts thoroughly. Apply clean Polaris PS-4 Synthetic Engine Oil
engine oil to all parts. Do not use gasket sealer on
the pump cover mating surfaces. Oil Pressure
2. Align the gerotor according to the orientation dots. Minimum Specification
(using Polaris PS-4 at operating temperature)
3. Place the drive pin q through the oil pump drive 10 PSI @ 1200 RPM (Minimum)
shaft. 40 PSI @ 7000 RPM (Minimum)
4. Slide the gerotor w onto the drive shaft and lock
them into position on the drive pin.
5. Install the washer e onto the drive shaft. CRANKCASE BREATHER SERVICE
NOTE
The crankcase breather is serviceable with the engine
assembled and installed in the vehicle chassis.
1. Remove the crankcase vent tube (if not already

performed).
2. Remove the two fasteners securing the engine
breather cover to the engine.
3. Remove the breather cover gasket and replace if CRANKCASE SEPARATION

damaged.
NOTE
4. For reassembly, thoroughly clean the crankcase and
breather cover mating surfaces. Install a new gasket Before the crankcase can be separated, be sure the
and torque the two fasteners to specification. entire top end and oil pump assembly are removed
from the engine as outlined in this chapter.
TORQUE
Crankcase Breather Cover Bolts: 1. Rotate the engine on the engine stand so the
9 ft-lbs (12 Nm) magneto side is facing upward.
2. Remove the oil filter and the three fasteners w (20ft-
lbs (28Nm) apply loctite 272) that secure oil filter 3
adapter q to the crankcase. Discard O-rings and
through clean the adaptor for reassembly.
3. Remove and discard the fifteen flange bolts from

magneto side crankcase evenly in a criss-cross
pattern.
4. Separate crankcase by tapping with a soft faced 2. Pull upward on the balance shaft and remove it from
hammer in reinforced areas and lift MAG crankcase the crankcase.
off PTO case.
3. Inspect drive gear for broken or damaged teeth.

CAUTION 4. Inspect bearing surfaces for scoring or signs of wear.
Never strike the engine mounts with a hammer.
BALANCE SHAFT REMOVAL / INSPECTION

1. Rotate crankshaft to align the timing marks as shown
below.
5. Inspect / replace the balance shaft bearings in both

crankcase halves. See “Crankcase Bearing
Inspection / Removal” procedure in this chapter.
NOTE
counterbalance shaft ball bearings must be inspected
visually and by feel. Look for signs of discoloration,
scoring or galling. Turn the inner race of each bearing.
The bearings should turn smoothly and quietly. The
outer race of each bearing should fit tightly in the
crankcase bore. The inner race should be firm with
minimal side to side movement and no detectable up
and down (radial) movement.
CRANKSHAFT REMOVAL CRANKSHAFT INSPECTION

1. Remove the engine from the engine stand and place
the assembly on a sturdy work bench. NOTE
The connecting rod uses plain bearings. The
2. Install the crankshaft removal / installation tool on to
the PTO side crank case. connecting rod bearings are not serviceable. If ANY
excessive wear or movement is present or if the rod
Crankshaft Removal / Installation Tool does not rotate on the crankshaft freely, the crankshaft
PU-50784 assembly must be replaced.
• Install plate q over adapter w. 1. Use a feeler gauge to measure the connecting rod
• Evenly attach the assembly onto the PTO side big end side clearance q. 3
crankcase using the four bolts as shown below.
• Thread the crankshaft removal screw e into w.
Connecting Rod Big End Side Clearance:

0.00590-.01771″ (.15 - .45mm)
2. Measure the connecting rod small end I.D. w.
3. With the help of an assistant holding the crankshaft,

slowly tighten the screw e until the crankcase is
completely separated from the crankshaft.
Small End I.D. Standard:
4. Remove all special tools from the crankcase.
0.8665 - 0.8670″ (22.010 - 22.023 mm)
3. Place the crankshaft in a truing stand or V-blocks 4. Support the crankcase and drive, press, or extract
and measure the runout where indicated below with the three bearings with a blind bearing remover.
a dial indicator.
Maximum Runout:
Mag side (3) - 0.00118″ (0.03 mm)
PTO side (4) - 0.00590″ (0.15 mm)
PTO SIDE CRANKCASE BEARING SERVICE

Bearing Removal
NOTE
Look for signs of discoloration, scoring or galling. Turn
the inner race of each bearing. The bearings should
turn smoothly and quietly. The outer race of each REF DESCRIPTION
bearing should fit tightly in the crankcase. The inner Bearing Retainer Bolt
race should be firm with minimal side to side movement q 8 ft-lbs (11 Nm) apply loctite 272
and no detectable up and down movement.
Bearings are stressed during the removal process and w Bearing Retainer
must not be re-used!
Bearings:
1. Remove and discard the PTO side crankshaft seal. Apply Loctite® 641 to the inner
e race of each of the crank
Replace with new for assembly.
bearings.
2. If not already performed, remove the screws that
secure the bearing retainer to the case. r Bearing Spacer
3. Remove the retaining ring. t Retaining Ring
Installation MAG SIDE CRANKCASE BEARING

NOTE SERVICE
Bearing Removal
To ease bearing installation, warm the crankcase
evenly with a heat gun or place in an oven and heat to 1. Support the crankcase and drive, press, or extract
220-250° F. Place bearings in clean plastic wrap and the balance shaft bearing q with a blind bearing
set in a freezer for 10-20 minutes. remover.
5. Clean all bearings e and inspect for excessive wear. NOTE

The MAG side crankshaft plain bearing w is not
NOTE serviceable. Crankcase replacement is required if the
Apply Loctite® 641 to the inner race of each of the bearing is damaged or has excessive wear. The 3
crank bearings. crankshaft is reusable if it meets specifications and
MAG side bearing surface is not groved, pitted,
6. Lubricate all bearings e with clean engine oil. damaged or excessively worn.
7. Fully seat the new balance shaft bearing until

bottomed in the bearing bore.
8. Install the retaining ring t for the crankshaft
bearings.
9. Fully seat the new outer PTO crankshaft bearing
until bottomed against the retaining ring.
10. Install the bearing spacer r.
11. Press in the new inner PTO bearing until it is
bottomed against the bearing spacer.
12. Apply Loctite® 272™ to the two bearing retainer
bolts q.
13. Install the bearing retainer w and torque the fastener
to specification.
TORQUE IMPORTANT
Bearing Retainer Fastener: Due to extremely close tolerances and minimal wear,
the bearings must be inspected. Look for discoloration,
scoring or galling. The inner race of each bearing
should turn smoothly and quietly. The outer race of
each bearing should fit tightly in the crankcase. The
inner race should be firm with minimal side to side
movement and no detectable up and down movement.
Bearings are stressed during the removal process and
must not be re-used!
Installation
2. Clean all bearing bores and inspect for excessive
wear.
3. Lubricate all bearing bores with clean engine oil.
4. Fully seat the new balance shaft bearing until
bottomed in the bearing bore.
OIL PICKUP ASSEMBLY INSPECTION CRANKCASE INSPECTION

The oil pickup assembly is located in the Mag side 1. Remove all traces of gasket sealer from the
crankcase q. crankcase mating surfaces. Inspect the surfaces
closely for nicks, burrs or damage.
2. Be sure alignment pins are in place where used.
3. Be sure oil passages are clean and free of any
cleaning solvent.
1. Pull and twist to remove the oil pickup assembly from

the crankcase.
2. Inspect the assembly for cracks and excessive wear.
Replace if necessary.
3. Remove and discard the O-ring.
4. Thoroughly clean the pickup assembly
5. Replace the o-ring and lubricate with clean engine
oil.
6. Press the pickup assembly into the crankcase until
fully seated.
OIL PRESSURE REGULATOR (BYPASS)

VALVE INSPECTION
The oil pressure regulator (bypass) valve is located in the
Mag side crankcase w.
1. Use a brass drift to press out the oil pressure valve
from the crankcase.
2. Replace the oil pressure valve if the inner plunger
binds, sticks or does not operate smoothly.
3. Remove and discard the o-ring.
4. Thoroughly clean the valve.
5. Replace the o-ring and lubricate with clean engine
oil.
6. Press the oil pressure valve into the crankcase until
fully seated.
ENGINE ASSEMBLY - LOWER END

CRANKCASE ASSEMBLY – PTO SIDE 5. Install the crankshaft removal / installation tool on to
1. Lubricate all crankcase bearings with engine oil. the PTO side crankcase.
Clean sealing surface to remove all oil sealant. Crankshaft Removal / Installation Tool
PU-50784
NOTE
Apply Loctite® 641 to the inner race of each of the
• Install plate q over adapter w.
crank bearings.
• Evenly attach the assembly q onto the PTO side
crankcase flange using the four bolts provided with
2. Place crankcase on a sturdy work bench. tool. 3
3. Carefully set the PTO crankcase onto the PTO side • Place the nut and large washer onto the crankshaft
of the crankshaft. installation screwe.
• Insert the crankshaft installation screw through the
4. Align the connecting rod with the cylinder area of the threaded portion of the adaptor w.
crankcase. • Fully thread the crankshaft installation screw into the
clutch bolt threads of the crankshaft.
• With the help of an assistant holding the crankshaft,
firmly hold the crankshaft installation screw with a
wrench while tightening the large nut against the
adaptor w.
6. With the help of an assistant, slowly tighten the nut

until the crankshaft is completely seated into the
crankcase bearings.
7. Remove the crankshaft removal / installation tool
from the crankcase.
8. Be sure crankshaft is fully seated and rotates 10. Use the crankshaft removal / installation tool to
smoothly. properly drive the crankshaft seal into the crankcase.
Crankshaft Removal / Installation Tool
PU-50784
• Center plate q over the crankshaft so it is resting on

the crankshaft seal.
• Center adaptor w over the crankshaft end.
• Place the nut and large washer onto the crankshaft
installation screw.
• Insert the crankshaft installation screw through the
threaded portion of the adaptor.
• Fully thread the crankshaft installation screw into the
clutch bolt threads of the crankshaft.
• Firmly hold the crankshaft installation screw with a
wrench while tightening the large nut against the
adaptor.
NOTE
The crankshaft seal can be replaced with the engine
installed in the chassis. The engine does not have to be
removed and the crankcase does not have to be
separated to replace the crankshaft seal.
9. Lubricate a new crankshaft seal and slide it over the

PTO end of the crankshaft with numbers facing OUT.
Be sure seal lip does not fold back when moving
over the crankshaft flange.
11. Drive seal until flush with seal bore.
12. Turn PTO crankcase over and support with

crankshaft upright.
BALANCE SHAFT INSTALLATION / TIMING FINAL CRANKCASE ASSEMBLY

1. Position balance shaft in the crankcase. 1. Prepare lower crankcase by cleaning sealing
surface. Be sure the oil pickup and oil pressure valve
2. Rotate crankshaft to align the timing marks q as
are fully installed.
shown below.
2. Apply a thin film of Crankcase Sealant (PN 2871557)
3. Fully seat the balance shaft into the crankcase and
evenly to a clean and oil-free crankcase mating
verify timing marks are correct.
surface as indicated below q. Be sure alignment
pins w are in place.
Crankcase Sealant:
PN 2871557 3
3. Carefully assemble MAG crankcase to PTO
crankcase immediately. Do not allow sealant to dry.
4. Tap crankcase evenly until fully seated with a soft

sided hammer.
5. Install the new crankcase bolts finger tight in MAG

side crankcase.
6. Tighten all bolts evenly until snug.
7. Torque the new crankcase bolts to in sequence to

specification.
TORQUE
Crankcase Bolts (In Sequence):
22 ft-lbs (30 Nm)
8. Install the engine stand adapter onto the engine ears

as shown below.
Engine Stand Adapter:

PU-50824-A
9. Select the proper engine stand sleeve adapter and

install it onto the engine stand adapter.
Sleeve adapter for a 2″ bore engine stand:
PU-50625
Sleeve adapter for a 2.375″ bore engine stand:

PW-47054
10. Place engine onto the engine stand for top end
engine assembly as outlined in this chapter.
Engine Stand:
PU-50624-A
STARTER ONE-WAY CLUTCH FLYWHEEL INSTALLATION

INSTALLATION 1. Clean the threads q, taper w and flat e of
1. Install one-way clutch in clutch hub with flange of crankshaft to remove all oil or grease.
clutch q facing the flywheel.
2. Clean flywheel taper r with alcohol to remove all oil

or grease.
NOTE
The one-way clutch can be installed into the hub
incorrectly. This will cause engine cranking issues.
2. Clean screw threads in flywheel to remove all oil or

grease.
3. Apply Loctite® 272™ on the one way clutch retaining
bolts threads w. Place hub on flywheel and install
bolts.
4. Torque screws to specification.
3. Apply a small amount of PS4 engine oil to the flat

area t on the MAG side crankshaft. DO NOT apply
engine oil to the crankshaft taper.
TORQUE
One Way Clutch Retaining Bolts:
9 ft-lbs (12 Nm) Apply Loctite® 272™
4. Rotate crankshaft so the flywheel key y is facing

upward.
5. Fully install starter gear onto the crankshaft as 11. Torque new flywheel nut u to specification.
shown.
6. Align the flywheel keyway with flywheel key on the TORQUE

crankshaft. Flywheel Retaining Nut:
7. Thoroughly clean the crank taper with alcohol. 133 ft-lbs (180 Nm)
8. By hand, lightly press the flywheel inward while
rotating the starter gear counter clock-wise. Fully 12. Install starter idler gear i and shaft o.
install the flywheel until seated on the crankshaft
taper.
9. Install the flywheel washer.

10. Hold flywheel with commercially available strap
wrench.
STATOR / STATOR COVER INSTALLATION

1. Clean and degrease stator screws and threads in the
stator housing.
2. Clean mounting surfaces of stator q and housing w.
3. Apply crankcase sealant to edges of rubber stator
grommet.
4. Set the stator in housing and press wire grommet
into slot on housing.
5. Apply Loctite® 242™ to end (8-10 threads) of the
stator screws e and the wire routing bracket screws
3
r.
6. Install a new stator cover gasket.
7. Install the stator cover.
CAUTION
when installing the stator cover.
any time during the installation process or injury could
result.
8. Install the stator cover screws and torque to

specification.
TORQUE
Stator Mounting Bolts:
TORQUE
Stator Wire Retainer:
6 ft-lbs (9 Nm)
TROUBLESHOOTING • Dirt entering engine through cracks in air filter or ducts

• Engine oil dirty or contaminated
ENGINE
Excessive Smoke and Carbon Buildup
Spark Plug Fouling
• Excessive piston-to-cylinder clearance
• Spark plug cap loose or faulty • Worn rings, piston, or cylinder
• Incorrect spark plug heat range or gap • Worn valve guides or seals
• PVT system calibrated incorrectly/ components worn • Restricted breather
or mis-adjusted • Air filter dirty or contaminated
• Fuel quality poor (old) or octane too high
• Low compression Piston Failure - Scoring
• Restricted exhaust
• Lack of lubrication
• Weak ignition (loose coil ground, faulty coil, or stator)
• Dirt entering engine through cracks in air filter or ducts
• Restricted air filter (main or pre-cleaner) or breather
• Engine oil dirty or contaminated
system
• Improperly assembled air intake system Slow Engine Cranking
• Restricted engine breather system
• Oil contaminated with fuel • Weak battery
• Loose Electrical connections
Engine Turns Over But Fails To Start • Decompression Mechanism not functioning properly.
• No fuel Excessive Smoke and Carbon Buildup
• Dirt in fuel line or filter
• Excessive piston-to-cylinder clearance
• Fuel will not pass through fuel valve
• Wet sumping due to over-full crankcase
• Fuel pump inoperative/restricted
• Worn rings, piston, or cylinder
• Tank vent plugged or pinched
• Worn valve guides or seals
• Engine flooded
• Restricted breather
• Low compression (high cylinder leakage)
• Air filter dirty or contaminated
• No spark (Spark plug fouled) ignition component
failure Low Compression
Engine Does Not Turn Over • Cylinder head gasket leak
• No valve clearance (cam wear)
• Dead battery
• Cylinder or piston worn
• Starter motor does not turn
• Piston rings worn, leaking, broken, or sticking
• Engine seized, rusted, or mechanical failure
• Bent valve or stuck valve
Engine Runs But Will Not Idle • Valve spring broken or weak
• Valve not seating properly (bent or carbon
• Restricted fuel supply accumulated on sealing surface)
• Low compression • Rocker arm sticking
• Crankcase breather restricted
Backfiring
Engine Idles But Will Not Accelerate
• Fouled spark plug or incorrect plug or plug gap
• Spark plug fouled/weak spark • Exhaust system air leaks
• Broken throttle cable • Valve sticking
• Obstruction in air intake • Ignition system faulty:
• Air box removed (reinstall all intake components) • Spark plug cap cracked / broken
• Incorrect flywheel installation or sheared flywheel key. • Ignition coil faulty
• Restricted exhaust system • Ignition or kill switch circuit faulty
• Cam worn excessively • Poor connections in ignition system
• Ignition timing incorrect
Engine Has Low Power
• Sheared flywheel key
• Spark plug fouled
• Cylinder, piston, ring, or valve wear or damage (check
compression)
• PVT not operating properly
• Restricted exhaust muffler
• Cam worn excessively
Piston Failure - Scoring
• Lack of lubrication
COOLING SYSTEM
Overheating
• Low coolant level
• Air in cooling system
• Wrong type/mix of coolant
• Faulty pressure cap or system leaks
• Restricted system (mud or debris in radiator fins
causing restriction to air flow, passages blocked in
radiator, lines, pump, or water jacket, accident
damage)
•
•
Lean mixture (vents, fuel pump or fuel valve)
Fuel pump output weak
3
• Electrical malfunction
• Water pump failure/ Loose impeller
• Thermistor failure
• Cooling fan inoperative or turning too slowly (perform
current draw test)
• Low oil level
• Spark plug incorrect heat range
• Faulty hot light circuit
• Thermostat stuck closed or not opening completely
• Radiator is missing its internal diverter plate not
allowing coolant to flow through entire radiator
Temperature Too Low

• Thermostat stuck open
• Thermostat missing
Leak at Water Pump Weep Hole

• Faulty water pump mechanical seal (coolant leak)
• Faulty pump shaft oil seal (oil leak)
NOTES
FUEL SYSTEM
CHAPTER 4
FUEL SYSTEM
EFI OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
PRINCIPAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
INITIAL PRIMING / STARTING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
FUEL PRESSURE GAUGE KIT - PU-43506-A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
FUEL PRESSURE GAUGE ADAPTER - PA-48838 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6 4
DIGITAL WRENCH® - DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
DIGITAL WRENCH® DIAGNOSTIC SOFTWAREPU-47063-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
DIGITAL WRENCH® SMARTLINK MODULE KITPU-47471 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
DIGITAL WRENCH® - DOWNLOAD WEBSITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
EFI COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
EFI COMPONENT LOCATIONS - RIGHT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.8
EFI COMPONENT LOCATIONS - LEFT VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
LINE / HOSE ROUTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
FUEL LINE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.10
AIR BOX / INTAKE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
AIR BOX / AIR FILTER ASSEMBLY VIEW - 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
AIR BOX / AIR FILTER ASSEMBLY VIEW - 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.13
AIR BOX REMOVAL / INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.15
ELECTRONIC CONTROL UNIT (ECU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
ECU OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
RPM LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
ECU SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.16
ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.17
ELECTRONIC THROTTLE BODY (ETC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18
ETC OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18
ETC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18
ETC REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18
ETC LEARN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.18
PEDAL POSITION SENSOR (PPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19
PPS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19
PPS REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.19
FUEL TANK / PUMP / SENDOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20
FUEL TANK ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20
FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.20
FUEL TANK INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.21
FUEL SENDER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.21
FUEL PUMP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.22
FUEL PUMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.23
FUEL SYSTEM
TEMPERATURE / MANIFOLD ABSOLUTE PRESSURE (T-MAP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.26

T-MAP OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.26
T-MAP SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.26
T-MAP SENSOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.26
CRANKSHAFT POSITION SENSOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.27
CPS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.27
CPS TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.27
RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.27
AIR GAP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.28
ENCODER FLYWHEEL / KEYWAY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.28
CPS REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.29
IGNITION COIL OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.30
IGNITION COIL / WIRE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.30
IGNITION COIL / WIRE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.30
COIL PACK CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.30
SPARK PLUG WIRE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.30
FUEL INJECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.31
FUEL INJECTOR OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.31
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.31
FUEL INJECTOR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.31
FUEL INJECTOR TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.33
ENGINE COOLANT TEMPERATURE SENSOR (ETC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.34
ECT OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.34
ECT SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.34
SYSTEM OPERATION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.34
RESISTANCE VS. TEMPERATURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.34
ECT SENSOR REPLACEMENT - 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.35
ECT SENSOR REPLACEMENT - 570 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.35
EFI DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.36
SERVICE NOTES - FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.36
TROUBLE CODE DISPLAY (DTC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.37
DIGITAL WRENCH® OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.44
DIGITAL WRENCH® - DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.44
DIGITAL WRENCH® DIAGNOSTIC SOFTWARE OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.44
POLARIS MOBILE DIGITAL WRENCH (PMDW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.45
DIGITAL WRENCH® VERSION AND UPDATE ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.45
DIGITAL WRENCH® UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.46
DIGITAL WRENCH® COMMUNICATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.49
GUIDED DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.49
DIGITAL WRENCH® SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.50
DIGITAL WRENCH® FEATURE MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.50
ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.51
ECU REPROGRAMMING (REFLASH) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.51
ETC LEARN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.57
FUEL SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.58
FUEL STARVATION / LEAN MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.58
RICH MIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.58
FUEL SYSTEM
POOR IDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.58
FUEL SYSTEM
GENERAL INFORMATION
EFI OPERATION OVERVIEW
The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible
emissions. The ignition and injection functions are electronically controlled, monitored and continually corrected during
operation to maintain peak performance.
The central component of the system is the Bosch Electronic Control Unit (ECU) which manages system operation,
determining the best combination of fuel mixture and ignition timing for the current operating conditions.
An in-tank electric fuel pump is used to move fuel from the tank through the fuel line, to the fuel rail. The in-tank fuel
pressure regulator maintains a system operating pressure and returns any excess fuel back into the tank. At the
engine, fuel is fed through the fuel rail and into the injectors, which inject into the intake ports. The ECU controls the
amount of fuel by varying the length of time that the injectors are "on." This range can vary depending on fuel
requirements. The controlled injection of the fuel occurs every other crankshaft revolution, or once for each 4-stroke
cycle. The total amount of fuel needed for one firing of a cylinder is injected during each cycle. When the intake valve
opens, the fuel/air mixture is drawn into the combustion chamber, ignited and burned.
The ECU controls the amount of fuel being injected and the ignition timing by monitoring the primary sensor signals for
intake air temperature, manifold absolute pressure (load), engine temperature, speed (RPM), and throttle position.
These primary signals are compared to the programming in the ECU computer chip, and the ECU adjusts the fuel
delivery and ignition timing to match the values.
During operation, the ECU has the ability to re-adjust temporarily; providing compensation for changes in overall
engine condition and operating environment, so it will be able to maintain the ideal air/fuel ratio.
During certain operating periods such as cold starts, warm up, acceleration, etc., a richer air / fuel ratio is automatically
calculated by the ECU.
PRINCIPAL COMPONENTS INITIAL PRIMING / STARTING PROCEDURE

The Electronic Fuel Injection (EFI) system is a complete
engine fuel and ignition management design. This NOTE
system includes the following principal components: The injection system must be purged of all air prior to
• Fuel Pump the initial start up, and / or any time the system has
• Fuel Rail been disassembled.
• Fuel Line
• Fuel Filter(s) If the EFI system is completely empty of fuel or has been
• Fuel Injector disassembled and repaired:
• Pressure Regulators 1. Cycle the key switch from “OFF” to “ON” 6 times,
• Throttle Body / lntake Manifold waiting for approximately 3 seconds at each “ON”
• Engine Control Unit (ECU) cycle to allow the fuel pump to cycle and shut down.
• Ignition Coils
• Engine Coolant Temperature Sensor (ECT) 2. Once step 1 is completed, turn the key switch to
• Throttle Position Sensor (TPS) “START” until the engine starts or 5 seconds has
• Crankshaft Position Sensor (CPS) passed.
• Temperature and Manifold Absolute Pressure Sensor 3. If the engine failed to start, repeat step 1 for 2 more
(T-MAP) cycles and attempt to start the engine.
• Electronic Throttle Control (ETC)
If the engine fails to start, a problem may still exist,
• Wire Harness Assembly
and should be diagnosed.
• Check Engine Light
NOTE
Accurate testing of EFI components is recommended
utilizing the Digital Wrench® Diagnostic Software
(dealer only).
FUEL SYSTEM
SPECIAL TOOLS
FUEL SYSTEM
FUEL PRESSURE GAUGE KIT - PU-43506-A FUEL PRESSURE GAUGE ADAPTER - PA-
48838
NOTE
Used in conjunction with PA-48838 to check fuel
The EFI fuel system remains under high pressure, even pressure.
when the engine is not running. Before attempting to
service any part of the fuel system, the pressure must
be relieved. The Fuel Pressure Gauge Kit has an
integrated pressure relief valve that can be used to
bleed off pressure.
WARNING
Gasoline is extremely flammable and explosive under
certain conditions.
Always stop the engine and refuel outdoors or in a well
ventilated area.
Do not smoke or allow open flames or sparks in or near
gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
DIGITAL WRENCH® - DIAGNOSTIC
induce vomiting. CONNECTOR
If you spill gasoline on your skin or clothing, The diagnostic connector q is located under the front
immediately wash it off with soap and water and console, under the steering column as shown.
change clothing.
burns may result.
Always wear safety goggles when working with high
pressure or flammable fluids. Failure to do so could
result in serious injury or complications.
FUEL SYSTEM
DIGITAL WRENCH® DIAGNOSTIC DIGITAL WRENCH® - DOWNLOAD

SOFTWARE WEBSITE
PU-47063-B Located at: www.polaris.diagsys.com
This dealer-only software installs on laptop computers
equipped with a CD drive and is designed to replace
multiple shop tools often used to test EFI components. It
also includes step-by-step diagnostic procedures to aid
technician repair and troubleshooting.
NOTE
If the PC you are using is not equipped with a 9 pin
serial port, a USB to serial port adaptor will be
necessary. It is recommended to use the DSA USB to
serial port adaptor which can be purchased through
DSA at: www.diagsys.com
4
DIGITAL WRENCH® SMARTLINK MODULE
KIT Download Digital Wrench® Updates:
PU-47471
This module kit contains the necessary cables and
hardware to communicate between the vehicle ECU and
the Digital Wrench® diagnostic software. Polaris dealers
can also order the following separately: SmartLink
Module PU-47468, Vehicle Interface Cable PU-47469
and PC Interface Cable PU-47470.
NOTE
For the most recent information on Digital Wrench®
software and update downloads please visit the
website: www.polaris.diagsys.com
FUEL SYSTEM
EFI COMPONENT LOCATIONS

EFI COMPONENT LOCATIONS - RIGHT VIEW
REF. COMPONENT
11 Fuel Pump / Sender
12 High Tension Wire / Spark Plug
13 Throttle Body (ETC)
14 Speed Sensor (Mounted to Transmission)
15 CPS
16 Stator (Magneto)
FUEL SYSTEM
EFI COMPONENT LOCATIONS - LEFT VIEW
EFI COMPONENT LOCATIONS – LEFT VIEW

REF. COMPONENT
1 Instrument Cluster
2 Ignition Switch
3 Battery
4 Starter Motor Solenoid
5 Regulator / Rectifier
6 Fuse / Relay Box
7 Starter Motor
8 ECU
9 Ignition Coil
10 Engine Temperature Sensor (ECT)
FUEL SYSTEM
LINE / HOSE ROUTING

FUEL LINE ROUTING
• The fuel supply line q is routed as shown below and
retained by a clip w at the front engine mount.
• The fuel vent line e is routed as shown below and
terminates at the fuel vent connector r that is inserted
in the frame.
FUEL SYSTEM
AIR BOX / INTAKE SYSTEM

AIR BOX / AIR FILTER ASSEMBLY VIEW - 325
FUEL SYSTEM

q Cover, Airbox
w Seal, Cover
e Airbox
r Plug, Drain
t Air Filter
y Intake Boot
u Clamp, Gear
i Clamps, Gear Torque to 24 in-lbs (2.5 Nm)
o Pre-Filter
a Box, Intake
s Plug, Drain
d Screw Torque to 8 ft-lbs (11 Nm)
f Seal, Engine, Inlet
g Screw
h Nut Torque to 18 ft-lbs (27 Nm)
j Asm - Breather Valve
k Springband - Clamp
l Hose - Vent, Eng
1( Clamp - Hose, Spring
FUEL SYSTEM
AIR BOX / AIR FILTER ASSEMBLY VIEW - 570
FUEL SYSTEM

q Cover, Airbox
w Seal, Cover
e Airbox
r Plug, Drain
t Air Filter
y Intake Boot
u Clamp, Gear
i Clamps, Gear Torque to 24 in-lbs (2.5 Nm)
o Pre-Filter
a Box, Intake
s Plug, Drain
f Seal, Engine, Inlet
g Screw
h Nut Torque to 18 ft-lbs (27 Nm)
j Hose - Breather
FUEL SYSTEM
AIR BOX REMOVAL / INSTALLATION 4. Remove the screw e and nut securing the bottom of
The air box assembly can be removed from the vehicle the air box assembly to the transmission bracket.
through the maintenance access panel located in the
rear storage box.
Air Box Removal Procedure
1. Lift the rear cargo box to access the airbox.
4
5. Remove the air box assembly.
2. Loosen the gear clamps q and the spring clamp w.
Air Box Installation Procedure

1. Install the air box bottom assembly back into the
engine compartment.
2. Reinstall the screw and nut securing the air box to the
3. Unlatch the air box cover. Remove the cover from the transmission mount. Torque nut to specification.
air box. TORQUE
Air Box Fastener:
18 ft-lbs (24 Nm)
3. Reinstall the air box cover. Verify the cover tabs

engage the air box. Lock the clamps to secure the
cover.
4. Reinstall the breather hose spring clamp. Reposition
the gear clamps to secure the intake hoses onto the
air box. Tighten gear clamps to specification.
TORQUE
Air Intake Hose Gear Clamps:
24 in-lbs (2.7 Nm)
FUEL SYSTEM
ELECTRONIC CONTROL UNIT (ECU)

ECU OVERVIEW 570 RPM Limit:
The ECU q is the central processing computer of the Max RPM Limit - Fuel / Spark Cutoff
entire EFI fuel/ignition management system. During 7500 rpm (All Gears)
operation, sensors continuously gather data which is
relayed through the wiring harness to input circuits within
the ECU. Signals to the ECU include: ignition (on/off),
crankshaft position and speed (RPM), throttle position,
ECU SERVICE
engine coolant temperature, intake air temperature, Never attempt to disassemble the ECU. It is sealed to
intake manifold absolute pressure and battery voltage. prevent damage to internal components. Warranty is void
The ECU compares the input signals to the programmed if the case is opened or tampered with in any way.
maps in its memory and determines the appropriate fuel All operating and control functions within the ECU are
and spark requirements for the immediate operating pre-set. No internal servicing or readjustment may be
conditions. The ECU then sends output signals to set the performed. If a problem is encountered, and you
injector duration and ignition timing. determine the ECU to be faulty, contact the Polaris
Service Department for specific handling instructions. Do
not replace the ECU without factory authorization.
The relationship between the ECU and the throttle
position sensor (TPS) is very critical to proper system
operation. If the TPS is faulty, or the mounting position of
the TPS to the throttle body is altered, the TPS must be
adjusted.
For the purpose of troubleshooting, a known-good ECU
from another Polaris Vehicle of the same model number
may be used without system or engine component
damage.
During operation, the ECU continually performs a

diagnostic check of itself, each of the sensors, and
system performance. If a fault is detected, the ECU turns
on the “Check Engine” light in the speedometer and
stores the fault code in its fault memory. Depending on
the significance or severity of the fault, normal operation
may continue, or "Fail-Safe" operation (slowed speed,
richer running) may be initiated. A technician can
determine the cause of the “Check Engine” light by
referencing the “Instrument Cluster Trouble Code
Display” and “Diagnostic Trouble Code Table” or by using
Digital Wrench®. The ECU requires a minimum of 7.0
volts to operate. The memory in the ECU is operational
the moment the battery cables are connected.
RPM LIMIT
To prevent engine over-speed and possible failure, an
RPM limiting feature is programmed into the ECU. If the
maximum RPM limit is exceeded, the ECU suppresses
the injection signals, cutting off the fuel flow and retards
the ignition timing. This process repeats it self in rapid
succession, limiting operation to the preset maximum.
325 RPM Limit:

Max RPM Limit - Fuel Injector Suppression.
8500 RPM (All Gears)
FUEL SYSTEM
ECU REPLACEMENT 4. With the ignition turned off, disconnect the wire
Although the need for ECU replacement is unlikely, a harness from the ECU. Lift the connector locking
specific replacement procedure is required to ensure that lever and rotate it up until the connector is free from
all essential data contained within the original ECU is the ECU.
transferred to the replacement ECU. This procedure NOTE
requires the use of Digital Wrench Software which is only
available at an authorized dealer. Therefore ECU Upon removing the ECU connector, you should hear a
replacement should only be done at an authorized “click” when the connector is fully open.
dealer.
5. To install, reverse the procedure and tighten any
NOTE fasteners to specification.
Refer to this procedure and carefully follow all
instructions provided in Digital Wrench . NOTE
Upon installing the ECU connector, you should hear a
1. Carefully follow the ECU replacement instructions “click” when the connector is fully closed.
provided in Digital Wrench to ensure that all 4
essential data contained within the original ECU is
transferred to the replacement ECU.
2. Remove seat and ECU cover q.
3. Remove the 4 screws w retaining the ECU.
FUEL SYSTEM
ELECTRONIC THROTTLE BODY (ETC)

ETC OVERVIEW ETC REPLACEMENT
NOTE 1. Lift the rear cargo box.
DO NOT attempt to service the ETC. The ETC is a non- 2. Remove the airbox and breather box (if equipped).
serviceable component and can only be tested using 3. Disconnect the wire harness from the ETC.
Digital Wrench®. If the ETC is faulty, the entire 4. Remove the bolts retaining the ETC housing to intake
assembly must be replaced. .
Mounted to the intake, the ETC acts as an electronically 5. Reverse these steps for installation. Torque the ETC
controlled throttle body. The ETC controls engine throttle housing retaining bolts and intake boot clamp to
operation to provide the proper air/fuel ratio needed for specification.
engine operation at all RPM ranges. The ETC controls TORQUE
engine RPM based off input provided by the Throttle
Control Sensor (TCS) and Electronic Control Unit (ECU). ETC Housing Retaining Bolts:
7 ft-lb (10 Nm)
ETC TEST Intake Boot Clamp:
35 in-lb (4 Nm)
Never attempt to disassemble the ETC assembly.
Warranty is void if the end cover is opened or tampered
with in any way.
All operating and control functions within the ETC are ETC LEARN PROCEDURE
pre-set. No internal servicing or adjustments may be
performed. If a problem is encountered, and you IMPORTANT
determine the ETC to be faulty, contact the Polaris This procedure MUST be performed on the vehicle
Service Department for specific handling instructions. Do whenever the ECU is replaced or reflashed or the
not replace the ETC under warranty without factory throttle body is replaced.
authorization.
Use Digital Wrench® to perform all troubleshooting of
this component. Use a Volt Ohm meter to test the vehicle 1. After the reflash / ECU replacement / throttle body
harness continuity between the ETC connector and ECU change, leave the key on (engine not running) for 60
connector. Refer to the wire diagram for pin-out details. If seconds. Do NOT crank the engine during this time.
the ETC is faulty, the entire ETC assembly must be 2. Turn the key off and wait 3 minutes. During this time,
replaced. the ECU will write values into memory and then
completely shut down.
3. Turn key back on and start the vehicle. The vehicle
should operate normally.
4. If the procedure was interrupted at any time, start
back at step 1.
FUEL SYSTEM
PEDAL POSITION SENSOR (PPS)

OPERATION OVERVIEW PPS REPLACEMENT
NOTE 1. Disconnect the PPS harness connection q located
on the accelerator pedal.
DO NOT attempt to service the PPS. The PPS is a non-
serviceable component and can only be tested using
Digital Wrench®. If the PPS is faulty, the entire throttle
pedal assembly must be replaced.
Mounted to the throttle pedal assembly, the PPS acts as

a pedal position sensor. The PPS provides accelerator
pedal position to the Electronic Control Unit (ECU) to
increase or decrease engine RPM using the Electronic
Throttle Control (ETC). The PPS is the primary input
used to control engine speed during vehicle operation. 4
PPS TEST
The PPS can be tested utilizing Digital Wrench® by
verifying that pedal position readout varies as the pedal
is pressed. Reference the Data Display section and be
sure the Pedal Position is displayed. With the ignition key 2. Remove the seat and disconnect the negative (-)
on for at least 15 seconds and engine not running, the battery cable.
Pedal Position will read approximately 9.6% when the 3. Remove the bolts w securing the accelerator pedal
pedal is released. With the pedal fully depressed, the assembly to the frame support.
Throttle Position will vary depending on what gear you 4. Remove the pedal assembly from the vehicle.
have selected.
• High/Neutral/Park/Invalid – 100%.
• Low – 100%
• Reverse – 100%
NOTE
If the PPS fails, disconnect the battery power for 10
min. and retest.
The Pedal Position Sensor is calibrated to the

accelerator pedal. If the PPS is faulty, the accelerator
pedal assembly must be replaced (see "PPS
Replacement").
FUEL SYSTEM
FUEL TANK / PUMP / SENDOR

FUEL TANK ASSEMBLY VIEW FUEL TANK REMOVAL
TORQUE WARNING
1: 75 ft-lbs (92 Nm) Fuel is extremely flammable and may cause severe
burns, injury, or death.
Do not use any device that produces a flame or
electrical devices that may spark around fuel or fuel
vapors.
1. Lift the rear cargo box

2. Remove the seat from the vehicle.
3. Disconnect the negative (-), and then positive (+)
battery cables from the battery.
4. While holding a shop towel over the fuel line
connector, disconnect the quick connect fuel line from
the fuel pump q. Move the fuel line out of the way for
tank removal.
NOTE
A small amount of fuel may come out of the fuel line or
tank. Properly drain fuel into a suitable container.
5. Disconnect the fuel pump electrical harness w.

6. Remove the fuel vent line from the tank vent fitting.
7. Remove the fuel cap, push rivets and screws
retaining the RH fender panel and remove panel from
the vehicle. See Floor and Fenders, page .
FUEL SYSTEM
8. Remove the four screws e securing the fuel tank to FUEL SENDER TEST
the frame support.
FUEL TANK INSTALLATION
WARNING
Fuel is extremely flammable and may cause severe
burns, injury, or death.
Do not use any device that produces a flame or
electrical devices that may spark around fuel or fuel
vapors.
Fuel Sender Resistance Specifications:
1. Carefully reinstall the fuel tank assembly Full: 6 ± 1 Ω
2. Reinstall the four fuel tank mounting screws and Empty: 90 ± 4.5 Ω
torque to specification.
TORQUE 1. Hook up an ohm meter to the Fuel Pump Module
connector terminal q and terminal w.
Fuel Tank Screw Torque:
17 Ft-Lbs (23 Nm)
3. Reinstall the RH fender panel, the fuel cap and all

previously removed fasteners.
4. Connect the fuel pump electrical harness, the fuel
line, and the vent line. Verify the fuel line is locked in
to place by lightly tugging on the connector at the fuel
pump.
5. Reconnect the negative battery cable. Test the fuel
pump by turning the ignition key on and listening for
the pump to activate. Check for leaks.
6. Reinstall the seat assembly.
• q Fuel Level Sender (+)

• w Fuel Level Sender (-)
• e Fuel Pump Power (+)
• r Fuel Pump Power Ground (-)
FUEL SYSTEM
2. With the sender float in the empty position, the 3. Install the Fuel Pressure Gauge Adaptor (PV-48656)
meter should read 6 ohms. in-line between the fuel pump outlet and fuel line.
3. With the float arm in the full position, the meter 4. Connect the hose from the Fuel Pressure Gauge Kit
should now read 90 ohms. (PU-43506-A) to the test valve on the Fuel Pressure
4. If the readings are not between 6 ohms and 90 Gauge Adaptor (PV-48656). Route the clear hose into
ohms, or if the reading is erratic or LCD display a portable gasoline container or the vehicle’s fuel
“sticks”, check the following before replacing the tank tank.
assembly.
• Loose float
• Float contact with tank
• Bent Float Rod
If the float/arm are not damaged or contacting the
tank restricting movement, and resistance is out of
specification, the sender assembly is faulty. The
sender is not serviceable separately, the Fuel Pump
Module must be replaced as an assembly.
FUEL PUMP TEST

If a fuel delivery problem is suspected, make certain the
fuel pump filters are not plugged, that the pump is being
activated through the ECU, all electrical connections are
properly secured, the fuses are good, and a minimum of
7.0 volts is being supplied. If during starting the battery
voltage drops below 7.0 volts, the ECU will fail to operate
the system.
WARNING
certain conditions.
ventilated area.
gasoline is stored.
gasoline, seek medical attention immediately. Do not 5. Turn on the key switch to activate the pump and
induce vomiting. check the system pressure on the gauge. If system
If you spill gasoline on your skin or clothing, pressure of 58 ± 2 psi is observed, the ignition switch,
immediately wash it off with soap and water and ECU, fuel pump, and pressure regulator are working
change clothing. properly. Turn the key switch off and depress the
Never start the engine or let it run in an enclosed area. valve button on the tester to relieve the system
Engine exhaust fumes are poisonous and can result pressure.
Never drain the fuel when the engine is hot. Severe Normal Fuel Pressure:
burns may result. 58 ± 2 psi (400 ± 14 kPa)
result in serious injury or complications. NOTE
If the fuel pressure is out of specification, replace the
fuel pump assembly.
1. Access the top of the fuel pump. Refer to “Fuel
Pump Replacement”, page for more detail.
2. Cover the fuel line connection at the fuel tank with a
shop towel and disconnect the line from the fuel
pump outlet.
FUEL SYSTEM
6. If the pump did not activate (Step 5), disconnect the FUEL PUMP REPLACEMENT
harness connector from the fuel pump. Connect a DC
voltmeter across terminals “3” and “4” in the plug on WARNING
the vehicle fuel pump harness. Turn on the key switch
and observe voltage to ensure a minimum of 7 volts is Gasoline is extremely flammable and explosive under
present. certain conditions.
ventilated area.
gasoline is stored.
induce vomiting.
4
change clothing.
burns may result.
NOTE
CAUTION
If the voltage was below 7 VDC, test the battery, ignition
switch, relay(s), wiring harness and ECU. It is possible for pressurized fuel to be present when
disconnecting the fuel line.
It is recommended to allow the vehicle to sit for a period
7. If the reading is between 7 and 14 volts, turn key of one hour after shutting off the engine before
switch off and connect an ohmmeter between servicing the fuel pump. This allows the exhaust to cool
terminals “3” and “4”' at the white fuel pump and fuel pressure to drop.
connector to check for continuity within the fuel pump.
NOTE 1. Remove the seat to access the fuel pump.

If there was no continuity between the pump terminals, 2. Disconnect the battery (-) negative cable.
replace the fuel pump assembly.
3. Ensure that static has been discharged from you by
touching a ground source such as the engine or
8. If voltage at the plug was within the specified range, frame.
and there was continuity across the pump terminals, 4. While holding a shop towel over the fuel line
reconnect the plug to the fuel pump, making sure you connector, disconnect the quick connect fuel line q
have a clean connection. Turn on the key switch and from the fuel pump.
listen for the pump to activate.
NOTE
NOTE
A small amount of fuel may come out of the fuel line or
If the pump starts, repeat steps 3, 4 and 5 to verify tank. Properly drain fuel into a suitable container.
correct pressure.
9. If the pump still does not operate, check for correct

ECU operation by plugging in a known-good ECU of
the same model.
NOTE
If the pump still does not operate, replace the fuel pump
assembly.
FUEL SYSTEM
WARNING
Failure to clean area around fuel pump may lead to
debris entering the fuel tank during service. Excessive
debris in fuel tank may cause premature wear of fuel
pump and/or clogging of internal fuel filters.
7. Place the Fuel Pump Service Tool (PU-50326) over

the fuel pump PFA nut. Using a 1/2” drive ratchet or
breaker bar, loosen and remove the PFA nut. Discard
the PFA nut.
NOTE
Apply downward force on the fuel pump flange while
removing the fuel pump PFA nut.
5. Disconnect the fuel pump electrical harness w.
6. Be sure the top of the fuel tank is clean. If it requires 8. Carefully lift the fuel pump out of the fuel tank. As the
cleaning, hand wash the top of the tank e to ensure fuel pump assembly is being removed, be aware of
no debris will enter the fuel system when the fuel float arm and pump pre-filter. Hold the float arm to the
pump is removed. pump body as you lift and tilt the pump to ensure that
the float arm is not bent when removed from the tank.
9. Transfer old fuel pump to a suitable container capable

of safely holding fuel. The fuel pump will retain some
fuel.
10. Inspect the inside of the fuel tank for debris (may
require flashlight and mirror). If debris like mud or
FUEL SYSTEM
sand is present, fuel tank should be flushed and

WARNING
cleaned out prior to installation of new fuel pump
assembly. Failure to align the orientation marks may lead to
interferences with the fuel level float arm and cause
NOTE incorrect function.
It is recommended to remove the fuel tank from the
vehicle and rinse it with a small amount of clean fuel. 17. While maintaining downward pressure, thread new
Do not use water or any other chemicals to remove PFA nut onto fuel tank and hand tighten. Use care
debris. when starting PFA nut, ensuring threads are properly
aligned. Verify orientation marks are still aligned
11. Remove new fuel pump assembly, gasket and PFA between fuel pump and fuel tank.
nut from packaging. Use care not to bend float arm 18. Torque PFA nut to specification using the Fuel Pump
when unpacking. Do not lift or carry fuel pump Service Tool (PU-50326) and a calibrated torque
assembly by the float arm. wrench.
12. Use cleaning wipes provided to clean fuel tank
surface and threads. Remove all debris, grease and
TORQUE 4
oil. Allow surfaces to dry completely. Fuel Pump PFA Nut:
70 ± 5 ft-lbs (95 ± 7 Nm)
13. Install new PFA gasket onto fuel pump assembly
using care not to damage gasket or bend float arm.
14. Install fuel pump into fuel tank, hold float arm to the 19. Verify alignment of fuel pump and tank orientation
pump body and tilt assembly to ensure float arm does marks.
not get caught or bent during installation. 20. Connect the fuel line to the fuel pump outlet.
15. Gently push down on fuel pump flange ensuring
flange is centered. NOTE
16. Roughly align orientation mark on fuel pump between Be sure to engage the retainer on fuel line until it snaps
the orientation marks on fuel tank to ensure float arm into place. Pull on fuel line lightly to confirm connection.
does not get bent or snagged. The arrow on the fuel
pump should be between the two marks on the fuel 21. Connect the fuel pump electrical harness.
tank
22. Connect battery.
23. Install the seat.
24. Test the fuel pump by turning on the key and listening
for the pump to activate. Cycle the key several times
to prime the system and check for leaks.
FUEL SYSTEM
TEMPERATURE / MANIFOLD ABSOLUTE PRESSURE (T-MAP)

T-MAP OVERVIEW T-MAP SENSOR TEST
Mounted on the throttle body intake manifold, the T-MAP The T-MAP sensor should be tested using Digital
sensor performs two functions in one unit. Wrench. When connected to Digital Wrench, observe the
Intake Air Temperature reading and the Manifold
Air passing through the intake is measured by the T-MAP
and relayed to the ECU. These signals, comprised of Absolute Pressure reading. Intake Air Temperature and
Manifold Absolute Pressure should be close to what the
separate air temperature and manifold absolute pressure
temperature is in your environment when the key is
readings, are processed by the ECU and compared to its
turned on, engine not running. When the vehicle is
programming for determining the fuel and ignition
started, manifold absolute pressure will be around 9 PSI
requirements during operation. The T-MAP sensor
(cold engine) and drop to around 6 PSI (warm engine). If
provides the ECU with engine load data.
unsure about the readings, compare to a known good
unit.
Wiring harness issues are more likely to be the cause of
a poor running condition than a faulty T-MAP.
The T-MAP sensor is a non-serviceable item. If it is
faulty, it must be replaced.
T-MAP SENSOR REPLACEMENT

1. Remove the seat and disconnect the negative (-)
battery cable.
2. Remove the cargo box access panel.
3. Disconnect vehicle harness from T-MAP sensor.
4. Remove the retaining bolt q and remove the sensor
w from the intake boot.
5. Use a light coating of soapy water on the grommet e
to aid installation of the new sensor.
6. Install the sensor w by inserting it with a twisting
motion to properly seat the grommet e.
7. Install the retaining bolt and torque to specification.
TORQUE
T-MAP Retaining Bolt:
24 in-lbs (2.8 Nm)
FUEL SYSTEM
CRANKSHAFT POSITION SENSOR

CPS OVERVIEW CPS TEST
NOTE
The CPS is a sealed, non-serviceable assembly. If fault
code diagnosis indicates a problem with this sensor
circuit, test as follows:
RESISTANCE TEST
1. Access the CPS connector.
2. Disconnect CPS from the main harness connector.
3. Measure the resistance between the CPS terminals
shown below q using an ohmmeter. Verify the
resistance at room temperature is within specification. 4
CPS Resistance Specification:
Mounted on top of the stator cover, the crankshaft 1000 Ω ± 10%
position sensor q is essential to engine operation,
constantly monitoring the rotational speed (RPM) and
position of the crankshaft.
4. If the resistance is incorrect, follow the “CPS

Replacement” procedure.
5. If the resistance is correct, thoroughly inspect the
A ferromagnetic 35-tooth encoder ring w with a missing relevant wiring connections and chassis harness. An
tooth is built onto the flywheel. The inductive speed electrical component , connection, or harness issue
sensor is mounted 1.0 ± 0.26 mm (0.059 ± 0.010″) away may persist.
from the encoder ring. During rotation, an AC pulse is 6. If all electrical connections have been verified and
created within the sensor for each passing tooth. The problems persist, proceed to the next test.
ECU calculates engine speed from the time interval
between the consecutive pulses. 7. Disconnect the ECU connector. Check continuity from
one wire at the CPS connector to the other end of the
The encoder ring missing tooth creates an “interrupt” circuit at the ECU connector. It should have less than
input signal, corresponding to specific crankshaft one ohm of resistance. If more than one ohm, locate
position. This signal serves as a reference for the control the cause of high resistance and recheck.
of ignition timing by the ECU. Synchronization of the
CPS and crankshaft position takes place during the first 8. If under one ohm on both wires, leave one meter lead
two revolutions each time the engine is started. This on one CPS circuit wires with both connectors still
sensor must be properly connected at all times. If the disconnected. Place the other lead on the battery
sensor fails or becomes disconnected for any reason, the negative terminal. Check both wires in this matter.
engine will stop running. They should both read OL, indicating no shorts to
ground.
9. If resistance of the wires to the ECU are in spec and
not shorted to chassis ground, test the shield wire for
good continuity to ground (under one ohm).
FUEL SYSTEM
10. If continuity to ground on the shield is in specification, 6. Subtract the sensor length from the sensor mounting
inspect harness routing compared to a known good point to encoder flywheel measurement. Verify that
vehicle, as well as for accessories that may create the calculated air gap is within specification.
interference. Routing close to ignition cables, stator
wires, or HID bulbs and other high voltage MEASUREMENT
accessories may cause issues. CPS Air Gap:
1.0 ± 0.26 mm (0.059 ± 0.010″)
NOTE
It should be noted that dynamic operation is what is
read by the ECU, not static testing like resistance
measuring as advised here. While the static tests
advised will lead to properly diagnosing almost all
situations, there are failure modes that will not be
noticed by resistance testing and still set trouble codes.
If there are concerns, please contact Technical Service
for guidance.
AIR GAP TEST

NOTE
The CPS air gap is non-adjustable, however
differences in air gap readings may indicate an
improper or damaged CPS sensorq or flywheel w. If
• If the resistance and air gap is correct proceed to
improper components are suspected, compare the
Encoder Flywheel / Keyway Inspection.
components to known good components.
• If the air gap is incorrect, compare the CPS flange
to sensor face measurement to a known good
Measuring the air gap between the CPS sensor q and sensor. If the sensor is correct proceed to Encoder
flywheel encoder w must be done using multiple Flywheel / Keyway Inspection.
measurements as the stator cover design does not • Is the CPS sensor is incorrect, follow the “CPS
allow direct air gap measurement. Replacement” procedure.
ENCODER FLYWHEEL / KEYWAY INSPECTION
1. Disconnect the CPS q from the main harness.
1. Access the CPS.
2. Remove the CPS.
2. Disconnect the CPS from the main wiring harness.
3. Measure the distance between the sensor mounting
flange and the bottom face of the sensor. 3. Drain the coolant.
4. Rotate the engine until a tooth of the encoder NOTE
flywheel is positioned in line with the CPS mounting Properly dispose of the coolant.
location.
5. Using a depth gauge, measure the distance from the
encoder flywheel tooth to the mounting surface of the 4. Disconnect the coolant hose at the water pump.
CPS. 5. Remove the fasteners retaining the stator cover.
FUEL SYSTEM
6. Inspect the flywheel for corrosion, warping, and CPS REPLACEMENT

damaged or missing components.
1. If not done already; disconnect the CPS harness
NOTE connector.
At this time measure flywheel run-out using a dial 2. Using an 8 mm socket, remove the CPS retaining bolt
indicator near the teeth on the flywheel. If the run-out and remove the sensor from the stator cover.
causes the CPS air gap to be out of tolerance, identify 3. Install new sensor using a light coating of oil on the
whether the flywheel is out of round, or if the crankshaft O-ring to aid installation.
is bent.
4. Torque the CPS and heat shield retaining bolts (if
equipped) to specification.
• If the resistance test, air gap test, and flywheel
inspection all test good, remove the flywheel and TORQUE
verify the keyway is in good working order. If the
keyway is intact and problems persist, thoroughly CPS Retaining Bolt:
inspect the relevant wiring connections as a 9 ft-lbs (12 Nm)
electrical component or connection may persist. 4
7. Install the stator if removed (see Engine / Cooling
System chapter).
8. Install the stator cover if removed (see Engine /
Cooling System chapter).
9. Install a NEW or known good CPS. (see CPS
Replacement).
10. Fill and bleed the coolant system (see Engine /
Cooling System chapter)
FUEL SYSTEM
IGNITION COIL OVERVIEW

IGNITION COIL / WIRE OVERVIEW SPARK PLUG WIRE CONNECTIONS
The ignition coil uses induction to convert high current,
low voltage in the primary ignition coil winding into low
current, high voltage in the secondary ignition coil
winding. The secondary side is the output that goes to
the ignition wire/cable, and then to the spark plug. The
circuit is completed to ground through the cylinder head
and then through engine ground back to the coil. When
the ignition key is on, DC voltage is present in primary
side of the ignition coil windings.
Spark is induced by the ECU opening the ground leg of
the coil circuit. This causes the magnetic field in the
primary to collapse, causing self induction and a great
voltage increase in both the primary and secondary. This
causes voltage to become high enough in the secondary
circuit that it can jump the spark plug gap.
IGNITION COIL / WIRE TEST

The ignition coil can be tested using an digital multimeter.
Use the following specification table and illustrations to
test the ignition coil.
TEST CONNECTION RESISTANCE
Primary Coil Coil Pack + and – 0.50Ω +/- 10%
Pins
Secondary Coil Coil Pack – and 6.6kΩ +/- 10%
Spark Plug Wire
Terminal
Spark Plug Wire Wire Connector 7.0kΩ +/- 10%
Terminal and
Spark Boot
Terminal
COIL PACK CONNECTIONS
FUEL SYSTEM
FUEL INJECTOR
FUEL INJECTOR OVERVIEW FUEL INJECTOR TEST
The fuel injector is mounted into the cylinder head, with The fuel injector is non-serviceable. If diagnosis indicates
the fuel rail retaining it from the top end. O-rings on both a problem with the injector, test the resistance of the fuel
ends of the injector prevent external fuel leaks and also injector solenoid windings by measuring between the two
insulate the injectors from heat and vibration. terminals e:
When the key switch is on, the fuel rail is pressurized,
and the EFI relay provides voltage to the injectors.
During engine operation, the ECU completes the ground
circuit, energizing the injectors. The valve needle in each
injector is opened electromagnetically, and the pressure
in the fuel rail forces fuel down through the inside. The
“director plate” at the tip of the injector contains a series
of calibrated openings which directs the fuel into the
intake port in a cone-shaped spray pattern. 4
The amount of fuel injected is controlled by the ECU and
determined by the length of time the valve needle is held
open, also referred to as the “injection duration” or “pulse
width modulation”. It may vary in length depending on the
speed and load requirements of the engine.
Fuel Injector Resistance Specification:

11.4 - 12.6 Ω
FUEL INJECTOR REPLACEMENT
WARNING
certain conditions.
ventilated area.
gasoline is stored.
induce vomiting.
change clothing.
burns may result.
FUEL SYSTEM
CAUTION
It is possible for pressurized fuel to be present when
disconnecting the fuel line.
It is recommended to allow the vehicle to sit for a period
of one hour after shutting off the engine before
servicing the fuel pump. This allows the exhaust to cool
and fuel pressure to drop.
1. Tilt the cargo box.

2. Be sure the engine has cooled enough to work on.
3. Remove the seat and disconnect the negative battery
cable.
4. Thoroughly clean the fuel injector area if all dirt and
debris. 12. Thoroughly clean the area around the fuel injector
5. Hold a shop towel over the fuel line fittings and port on the cylinder head.
remove the fuel supply line from the fuel rail. 13. Lightly lubricate the injector O-rings and reinstall the
6. Disconnect the harness from the fuel injector q. fuel rail / injector assembly into the cylinder head.
14. Install the fuel rail mounting screws and torque to
specification
TORQUE
Fuel Rail Mounting Screws:
7 ft-lbs (10 Nm)
15. Reinstall the fuel line to the fuel rail.

16. Connect the harness lead to the fuel injector.
17. Reconnect the negative battery cable and reinstall
the driver’s seat.
18. Cycle key ON several times to pressurize the fuel
system, and inspect the fuel rail and injector for fuel
leaks.
7. Remove the two screws e that mount the fuel rail w 19. Reinstall the cargo box access panel.
to the cylinder head.
8. Carefully pull up on the fuel rail and injector to remove
them from the engine as an assembly. If the injector
stays in the cylinder head, grab the injector with your
fingers and gently pull and twist the injector unit to
remove from cylinder head. Take care not to damage
the fuel injector ends during removal.
9. Gently pull and twist to free the injector from the fuel
rail.
10. Upon installation of the new fuel injector, lightly
lubricate the injector O-rings to aid installation.
11. Install the new injector into the fuel rail. Be sure to
align boss in the injector with the slot in the fuel rail.
FUEL SYSTEM
FUEL INJECTOR TROUBLESHOOTING

Injector problems typically fall into three general
categories- electrical, dirty / clogged, or leakage. An
electrical problem usually causes injectors to stop
functioning. Several methods may be used to check if the
injectors are operating.
• With the engine running at idle, feel for operational
vibration, indicating that they are opening and closing.
• When temperatures prohibit touching, listen for a
buzzing or clicking sound with a screwdriver or
mechanic's stethoscope.
• Disconnect the electrical connector from an injector
and listen for a change in idle performance (only
running on one cylinder) or a change in injector noise
or vibration.
NOTE
4
Do not apply voltage directly to the fuel injector.
Excessive voltage will burn out the injector. Do not
ground the injector with the ignition on. The fuel injector
will open/turn on if relay is energized.
If an injector is not operating, it can indicate either a bad

injector, or a wiring/electrical connection problem. Check
as follows:
Injector leakage is very unlikely, but in rare instances it
can be internal (past the tip of the valve needle), or
external (weeping around the injector body). The loss of
system pressure from the leakage can cause hot restart
problems and longer cranking times.
Injector problems due to dirt or clogging are unlikely due
to the design of the injectors, the high fuel pressure, the
use of filters and the detergent additives in the gasoline.
Symptoms that could be caused by dirty/clogged
injectors include rough idle, hesitation/stumble during
acceleration, or triggering of fault codes related to fuel
delivery. Injector clogging is usually caused by a buildup
of deposits on the director plate, restricting the flow of
fuel, resulting in a poor spray pattern. Some contributing
factors to injector clogging include; dirty air filters, higher
than normal operating temperatures, short operating
intervals and dirty, incorrect, or poor quality fuel.
Cleaning of clogged injectors is not recommended; they
should be replaced. Additives and higher grades of fuel
can be used as a preventative measure if clogging has
been a problem.
FUEL SYSTEM
ENGINE COOLANT TEMPERATURE SENSOR (ETC)

ECT OVERVIEW 6. Safely position the ETC so that the sensor is
Mounted on the cylinder head, the engine temperature submerged in water from the threads down and the
sensor measures coolant temperature. The engine connector may be readily probed.
temperature sensor is a Negative Temperature
NOTE
Coefficient (NTC) type sensor, as the temperature
increases, the resistance decreases. This signal is Use a wire or other type of prop to ensure the sensor is
processed by the ECU for determining the fuel and properly supported and the tip of the sensor is touching
ignition requirements during operation. The ECU also water only.
uses this signal to determine when to activate the fan.
7. Prepare a table similar to the one below, then heat
ECT SENSOR TEST the water and document the resistance measured
between pin 1 and pin 2 as the water and sensor
SYSTEM OPERATION TEST warm. If the Sensor tests out of tolerance, the sensor
To quickly rule out other components and wiring related should be replaced.
to the ECT, disconnect the harness from the ECT sensor
and start the engine. After a few seconds, the fan should ECT Sensor Resistance Readings
turn on and the “Check Engine” indicator should display
on the instrument cluster. This indicates all other TEMPERATURE °F (°C) RESISTANCE
components are working properly. 68 °F (20 °C) 2.5 k Ω ± 6%
86 °F (30 °C) 1.7 k Ω ± 6%
104 °F (40 °C) 1.2 k Ω ± 6%
122 °F (50 °C) 834 Ω ± 6%
140 °F (60 °C) 596 Ω ± 6%
158 °F (70 °C) 435 Ω ± 6%
176 °F (80 °C) 323 Ω ± 6%
194 °F (90 °C) 243 Ω ± 6%
212 °F (100 °C) 186 Ω ± 6%
RESISTANCE VS. TEMPERATURE TEST

CAUTION
Contact with boiling water or steam may cause burns.
1. Disconnect the ECT from the main harness.

2. Remove the ECT.
3. Fill a pot of water 1/2 way with water.
4. Place a pot of water on a hot plate.
5. Place the sensor / tip of a thermometer in the water,
ensure the display is legible as you will reference the
thermometer throughout the test.
FUEL SYSTEM
ECT SENSOR REPLACEMENT - 325 TORQUE

1. Lift the rear cargo box ETC Fasteners
2. Drain coolant to level below sensor. 7 ft-lbs (10 Nm)
3. Disconnect harness from the sensor q.
6. Add the required amount of coolant and properly
bleed the cooling system (see Engine chapter).
ECT SENSOR REPLACEMENT - 570

1. Lift the rear cargo box
2. Drain coolant to level below sensor.
3. Disconnect harness from the sensor q.
4. Using a wrench, remove and replace the sensor,

applying a light coating of thread sealant to aid
installation.
5. Torque the sensor to specification.
4. Using a wrench, remove and replace the sensor,

applying a light coating of thread sealant to aid
installation.
5. Torque the sensor to specification.
TORQUE
ETC Fasteners
7 ft-lbs (10 Nm)
6. Add the required amount of coolant and properly

bleed the cooling system (see Engine chapter).
FUEL SYSTEM
EFI DIAGNOSIS
SERVICE NOTES - FUEL SYSTEM
For more convenient and accurate testing of EFI
components, it is recommended dealers utilize the Digital
Wrench® Diagnostic Software (dealer only), or limited
testing may be done manually using procedures
provided.
80% of all EFI problems are caused by wiring harness
connections. Follow a common sense approach when
diagnosing a potential EFI issue:
1. Disconnect harness at suspected sensor connector.
2. Inspect the connector ends for damage or
contamination. If damaged, repair; if contaminated,
clean. Reconnect and check function.
3. If problem persists, perform a sensor bench test (if
applicable) according to sensor requirements.
4. If the sensor bench tests pass, disconnect the
connector at the ECU and perform a continuity check
between the sensor connector and the appropriate
pin at the ECU connector (all connections for that
sensor). Wiring resistance should be less than one
(1) ohm. With the sensor and ECU still disconnected,
check each leg of the circuit for continuity to ground,
you should have no continuity.
5. If the resistance is high (or open), a wiring harness
inspection is required (including a thorough
inspection of the ECU connector for contamination or
damage).
6. If the sensor and wiring passes inspection, and
reconnecting the ECU does not resolve the issue,
use a known-good ECU to test for problem
resolution.
• Never attempt to service any fuel system component
while engine is running or ignition switch "on".
• USE CARE when removing or installing the ECU
connector, as well as all other harness connections on
the unit. Properly connect and disconnect the ECU
harness to minimize damage to the connector pins and
locking mechanism.
• Although every precaution has been taken to prevent
water intrusion failure, avoid direct water or spray
contact with system components.
• Do not disconnect or reconnect the wiring harness
connector to the ECU or any individual components
with the ignition "on." This can send a damaging
voltage spike through the ECU.
• Do not allow battery cables to touch opposite
terminals.
• Never start the engine when the cables are loose or
poorly connected to the battery terminals.
• Never disconnect battery while engine is running.
• Always unplug ECU from the wire harness before
performing any welding on the unit.
FUEL SYSTEM
TROUBLE CODE DISPLAY (DTC) 3. A set of three numbers will appear in the information
area.
NOTE • The first number (located far left) can range from 0 to
The diagnostic mode is accessible only when the check 9. This number represents the total number of trouble
engine MIL has been activated. code present (example: 2 means there are 3 codes
present).
• The second number (located top right) can be 2 to 6
Use the following procedure to display diagnostic trouble
digits in length. This number equates to the suspected
codes that were activated during current ignition cycle
area of fault (SPN).
causing the MIL to illuminate. Diagnostic trouble codes
• The third number (located bottom right) can be 1 to 2
will remain stored in the gauge (even if MIL turns off) until
digits in length. This number equates to the fault mode
the key is turned off.
(FMI).
NOTE
If there is a diagnostic problem with the power steering
system, the power steering MIL will illuminate and blink
in place of the check engine MIL. 4
1. If the trouble code (s) are not displayed, use the
MODE button to toggle until “CK ENG” displays on
the information display area.
4. If more than one code exists, press the MODE button

to advance to the next trouble code.
5. To exit the diagnostic mode, press and hold the
MODE button or turn the ignition key OFF once the
codes are recorded.
2. Press and hold the MODE button to enter the
diagnostics code menu.
FUEL SYSTEM
DIAGNOSTIC TROUBLE CODE TABLE

COMPONENT CONDITION SPN FMI P-CODE
Not Plausible 2 P1225
Accelerator Position 2 Voltage Too High 29 3 P1228
Voltage Too Low 4 P1227
Valid But Above Normal 0 P1123
Valid But Below Normal 1 P1122
Data Erratic or Intermittent 2 P0121
Throttle Position Sensor 1 Voltage Too High 51 3 P0123
Abnormal Rate of Change 10 P0120
Out of Calibration 13 P1120
P0500
Valid But Above Normal 0 C1057
C1704
Data Erratic or Intermittent (or P0503
missing) 2
C1058
Voltage Above Normal 3 P1507
Voltage Below Normal 4 P1506
Vehicle Speed Signal 84
Abnormal Frequency or Pulse
8 P0501
Width
Abnormal Update Rate 9 P160A
Abnormal Rate of Change C1068
10
C1705
Bad Intelligent Device 12 P3503
Received Vehicle Speed Has Error P106B
19
C1069
Not Plausible 2 P0225
Accelerator Position 1 Voltage Too High 91 3 P0228
Voltage Above Normal 3
Fuel Level Signal 96
Voltage Below Normal 4
Data Erratic or intermittent 2 P0106
Voltage Too High 3 P0108
Manifold Absolute Pressure Voltage Too Low 4 P0107
Sensor (T-MAP) 102
Mechanical System Not
Responding 7 P1106
Valid But Above Normal 0
Intake Air Temperature (T-
Voltage Too Low 105 4 P0112
MAP)
Abnormal rate of Change 10 P0114
Valid But Above Normal
(least severe) 15 P0127
Engine Temperature Sensor
Engine Overheat Shutdown 110 0 P1217
(ECT)
FUEL SYSTEM

Temperature Too High 16 P0217
P0563
Voltage Too High 3
System Power
C1063
P0562
4
(Battery Potential / Power Voltage Too Low 168 4
Input) C1064
Valid But Below Normal
P0219
Valid But Above Normal 0
C1059
Valid But Below Normal 1 C1060
Engine Speed (This is Data Erratic or Intermittent 2 C1061
applicable when the EPS Mechanical System Not
module gets the engine speed Responding 190 7 P1219
from the ECM)
Received Engine Speed Has Error 19 C1066
Error in Engine Speed
Computation 31 P121C
Error in Engine Speed
Engine Speed 400 31 P121D
Computation
Date Erratic or Intermittent 2 P0914
Gear Sensor Signal 523
P1602
EEPROM: Read/Write Failure 12
C1073
ECU Memory 628
P0601
Out of Calibration 13
C1601
Calibration Checksum/CRC Error 630 13 C1074
Plausibility Fault 2 P0335
Crankshaft Position Sensor
(CPS) Abnormal Frequency or Pulse 636
8 P0336
Width
Camshaft Phase Sensor Circuit Fault 637 8 P0340
Driver Circuit Short to B+ 3 P0262
Injector 1 (MAG) Driver Circuit Grounded 651 4 P1262
Driver Circuit Open 5 P0261
Injector 2 (PTO) Driver Circuit Grounded 652 4 P1265
FUEL SYSTEM

Rear Differential Output Driver Circuit Grounded 746 4 P1693
Fan Relay Driver Circuit Driver Circuit Grounded 1071 4 P1483
Ignition Coil Primary Driver 1
Driver Circuit Grounded 1268 4 P1361
(MAG)
Ignition Coil Primary Driver 2
(PTO)
Fuel Pump Driver Circuit Driver Circuit Grounded 1347 4 P0231
Driver Circuit Open / Grounded 5 P0230
Data Erratic, Intermittent or
2 P0130
Incorrect
Voltage Above Normal or Shorted
to High Source 3 P0132
Oxygen Sensor 1 3056
Voltage Below Normal or Shorted
4 P0131
to Low Source
Bad Intelligent Device 12 P113A
Valid But Above Normal 0 P16A3
Valid But Below Normal 1 P16A6
Voltage Too High 3 P16A2
Voltage Too Low 4 P16A1
ECU Output Supply Voltage 1 3597
(least severe) 16 P16A5
(least severe) 18 P16A7
Valid But Above Normal 0 P16AA
Valid But Below Normal 1 P16AC
Voltage Too High 3 P16A9
Voltage Too Low 4 P16A8
(least severe) 16 P16AB
(least severe) 18 P16AD
Valid But Above Normal 0 P17AC
Valid But Below Normal 1 P17AE
Voltage Too High 3 P17AA
Voltage Too Low 4 P17AB
(least severe) 16 P17AD
(least severe) 18 P17AF
Misfire Detected Cylinder Not Identified 65590 7 P0314
FUEL SYSTEM

Cylinder 1 65591 7 P0301
Cylinder 2 65592 7 P0302
ETC Accelerator Position
Sensor Outputs 1 & 2 Correlation Fault 65613 2 P1135
Correlation
Date Erratic or Intermittent 2 P0221
Throttle Position Sensor 2 Voltage Too High 520198 3 P0223
Out of Calibration 13 P1220
4
All Wheel Drive Control Circuit
(AWD)
Chassis Relay Voltage Below Normal 520208 4 P1613
Open Circuit 5 P1611
Voltage Above Normal or Shorted
to High Source 3 P0032
Oxygen Sensor Heater 1 Voltage Below Normal or Shorted 520209
4 P0031
to Low Source
Current below Normal or Open
5 P0030
Circuit
Steering Over Current Shut Current Above Normal or
520221 6 C1050
Down Grounded
Steering Excessive Current Current Above Normal or
520222 6 C1051
Error Grounded
Steering Torque Partial Failure Condition Exists 520223 31 C1052
Steering Torque Full Failure Condition Exists 520224 31 C1053
Greater than 120° C (248° F) 0 C1055
EPS Inverter Temperature 520225
Greater than 110° C (230° F) 16 C1054
EPS CAN Communications No RX Message for 2 Seconds 2 U0100
520226
Receive Error Condition Exists 31 C1067
EPS CAN Communications No TX Message for 2 Seconds 520227 2 U1100
Transmit Error
Root Cause Unknown 11 C1065
Position Encoder Error Bad Intelligent Device 520228 12
Condition Exists 31 C106B
Bad Intelligent Device 12 C1070
EPS Software Error 520229
Condition Exists 31 C106F
IC CAN Communication with EPS Off Line (EPS DM1 not seen) 520230 31 U0131
EPS
EPS: Key On, Engine Off, 5 Minute
EPS Power Save Condition 520231 31 C1071
Power Save/Timeout
Idle Air Control Valve (IAC)
M17; IAC Stepper Pin 3 Driver Circuit Short to B+ 520268 3 P1519
FUEL SYSTEM

Driver Circuit Grounded 4 P1518
Responding 7 P1559
Out Of Calibration 13 P1302
Idle Air Control Valve (IAC) Driver Circuit Open / Grounded 5 P1525
M17; IAC Stepper Pin 4 520269
Responding 7 P1579
Responding 7 P1589
Responding 7 P1549
Accelerator Position / Brake
Condition Exists 520275 31 P150A
Position Interaction
Position Sensor Correlation Fault 2 P150C
Throttle Position Sensor
(1 or 2 Indeterminable) Neither Position Sensor Passed 520276
12 P150B
Test
Not Plausible 2 P151A
Voltage Above Normal 3 P150D
Throttle Body Control - Power Voltage Below Normal 4 P150E
Stage 520277
Signal Error 8 P151B
Deactivated power stages due to
5V sensor supply error 31 P153F
Throttle Body Control - Return
Spring Check Failed Condition Exists 520278 31 P151C
Throttle Body Control -
Adaptation Aborted Condition Exists 520279 31 P151D
Throttle Body Control - Limp
Condition Exists 520280 31 P151E
Home Position Check Failed
Mechanical Stop Adaptation Condition Exists 520281 31 P152A
Failure
Repeated Adaptation Failed Condition Exists 520282 31 P152B
Outside of Pedal Range (Level 1) 2 P152F
Throttle Body Control Voltage Above Normal 520283 3 P152C
Voltage Below Normal 4 P152D
FUEL SYSTEM

Condition Exists 520284 31 P152E
Position Deviation Fault
Brake Switch (1 or 2
Indeterminable) Brake Switch Correlation Fault 520285 2 P153E
ECU Monitoring Error Condition Exists 520286 31 P1540
ECU Monitoring Error (Level
3) Condition Exists 520287 31 P1541
ECU Monitoring of Injection
Cut Off (Level 1) Condition Exists 520288 31 P1542
ECU Monitoring of Injection
Cut Off (Level 2) Condition Exists 520289 31 P1543
Controller Option Setting Not
Out of Calibration 520290 13 P1544
Programmed 4
Requested Throttle Angle Not Condition Exists 520305 31 P1530
Plausible
ECU Analog to Digital
Condition Exists 520306 31 P1531
Converter Fault - No Load
ECU Analog to Digital
Converter Fault - Voltage Condition Exists 520307 31 P1532
Accelerator Sensor
Synchronicity Fault Sensor Condition Exists 520308 31 P1533
Difference Exceeds Limit
ECU Fault - ICO Condition Exists 520309 31 P1534
ECU Fault - Hardware
Disruption Condition Exists 520311 31 P1537
Adaptive Fuel Correction Bank Valid But Above Normal 15 P0170

520344
1 Valid But Below Normal 17 P1170
FUEL SYSTEM
DIGITAL WRENCH® OPERATION

DIGITAL WRENCH® - DIAGNOSTIC CONNECTOR
The diagnostic connector q is located under the front console, under the steering column as shown.
DIGITAL WRENCH® DIAGNOSTIC SOFTWARE OVERVIEW

NOTE
Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench® Diagnostic Kit to install the
Polaris Digital Wrench® diagnostic software on your computer.
The Digital Wrench® diagnostic software allows the technician to perform the following tests and observations:
• View or clear trouble codes
• Analyze real-time engine data
• Reflash ECU calibration files
• Perform guided diagnostic procedures
• Create customer service account records
• Perform output state control tests (some models)
FUEL SYSTEM
POLARIS MOBILE DIGITAL WRENCH (PMDW)

Polaris Mobile Digital Wrench (PMDW) is a diagnostic software application (app) designed specifically for Android™
devices. When paired with the Wireless Vehicle Link (WVL), part number PU-51435, PMDW provides Polaris service
technicians with many of the features and functions found in Digital Wrench.
PMDW Main Page:
Wireless Vehicle Link (WVL) – Part Number PU-51435:
To download the PMDW app, navigate your Android device to www. polarisdealers. com. Locate the Service and
Warranty drop-down menu. Select: “Mobile Digital Wrench App Download”. Tap on the link to download the app.
Android Device Minimum Specifications:
• Minimum operating system: Android 3.1 “Honeycomb” or higher (Android 4.0 or higher preferred)
• Dual core processor / 2 GB internal memory / external microSD (32 or 64 GB) slot / 500 MB RAM
• Rear facing camera with minimum 3.0 mega pixel resolution with auto/continuous focus
• Video, Microphone and Voice-to-text capable
• Internet and Bluetooth wireless technology capable
PMDW App Notes:

• PMDW will not work on Microsoft Windows 8™ or Apple IOS™ products
• Device must be set to allow the installation of non-market applications
• An electronic user’s guide is provided within the app. To access the user’s guide, launch the app, and then click on
the “Help” button in the Settings/Preferences menu.
• Only CAN-based vehicles are compatible with PMDW and the WVL. A complete list of compatible vehicles can be
found in the user’s guide.
DIGITAL WRENCH® VERSION AND UPDATE ID

Knowing what Digital Wrench® version and update is installed will help determine which updates are required.
FUEL SYSTEM
NOTE
Versions and updates are subject to change.
1. Open the Digital Wrench® software. Locate the version ID shown on the lower right side of the Digital Wrench®
start-up screen.
2. Proceed to http://polaris.diagsys.com to see if a newer update is available.
3. If a newer update is available, it should be downloaded before using Digital Wrench® (see “Digital Wrench®
Updates”).
NOTE
Always operate with the latest update.
DIGITAL WRENCH® UPDATES

Updates are released for Digital Wrench® via the Internet at: http://polaris.diagsys.com. The Digital Wrench® website
can also be accessed through the dealer website at: www.polarisdealers.com.
NOTE
Only authorized Polaris dealers and distributors can access the dealer website.
1. Log on to www.polarisdealers.com.
2. Locate the “Service and Warranty” drop-down menu.
FUEL SYSTEM
3. Click on “Digital Wrench Updates”.
4
4. The Digital Wrench® portal website should appear in a new web browser.
5. Click on “Digital Wrench Version Updates”.
NOTE
You must already have the current version installed before adding an update. Updates will not install if you are using
an older version loaded on your PC.
6. If the update file date listed is newer than your current version and update (see Chapter 4 to download the file.
7. Click on the link shown above, save the file to your hard disk and then double-click the icon to start the update
process.
NOTE
Do not "run" or "open" the file from where they are. Select "save" and download them to your PC before running the
install.
FUEL SYSTEM
8. When the update is complete, the version shown on the right side of the Digital Wrench® start-up screen should
match the update you just downloaded.
NOTE
Versions and updates are subject to change.
FUEL SYSTEM
DIGITAL WRENCH® COMMUNICATION ERRORS

If you experience problems connecting to a vehicle or any Digital Wrench® related problem, visit the Digital Wrench®
Knowledge Base for the most current troubleshooting information, FAQs, downloads and software updates at: http://
polaris.diagsys.com/.
GUIDED DIAGNOSTICS
Guided diagnostics are available within Digital Wrench® for all supported Trouble Codes (that is, any fault that will turn
on the ‘Check Engine’ indicator).
In addition, guided diagnostics are also available for many other electrical sub systems.
Diagnostic procedures are added to subsequent versions of Digital Wrench® as they become available. Check your
release version often and upgrade when available to be sure you are using the most current software available.
FUEL SYSTEM
DIGITAL WRENCH® SERIAL NUMBER LOCATION

Open the configuration screen by clicking on the wrench icon. The serial number is located on the right side of the
screen.
DIGITAL WRENCH® FEATURE MAP
View, or clear trouble codes

in the Engine Controller Enter / Edit / Change
Memory. Vehicle Information
This is the most viewed

screen. View sensor and Enter customer and vehicle
ECU information in a grid, information and view ECU
meter, or chart format. Identification.
View information from the Load the Vehicle Home

main ECU sensors. Page.
Set up data capture and Open the Software

record functions. Configuration Screen.
FUEL SYSTEM
Perform specialized testing

and adjustment functions Run the Help System.
service reports.
Open the ASSERT ASK Prints the current screen as

form. a formatted printout.
ECU REPLACEMENT
Although the need for ECU replacement is unlikely, a specific replacement procedure is required to ensure that all
essential data contained within the original ECU is transferred to the replacement ECU. 4
Refer to procedure and carefully follow all instructions provided in Digital Wrench®.
ECU REPROGRAMMING (REFLASH)

Process Overview
The reprogramming feature is in the Special Tests menu on the Digital Wrench® screen. Start Digital Wrench® and
click on the Special Tests menu icon (red tool box). A technician should be familiar with the process and with computer
operation in general before attempting to reprogram an ECU.
The Digital Wrench® Engine Controller Reprogramming (or “Reflash”) feature allows reprogramming of the ECU fuel
and ignition map. To successfully reprogram the ECU, an Authorization Key must be obtained by entering a Request
Code in the box provided on the Reflash Authorization site. The Request Code is automatically generated by Digital
Wrench® during the reprogramming process. The Reflash Authorization site is located under the “Service and
Warranty” drop down menu on the dealer website at: www.polarisdealers.com.
NOTE
Failure to follow the reprogramming instructions completely and correctly can result in an engine that does not run!
Replacement ECUs are programmed as “no-start” and require a reflash for them to work.
Reprogramming (Reflash) Tips:

• BATTERY VOLTAGE: The majority of problems with reprogramming can be attributed to a low battery. Be sure the
battery voltage (no load) is at least 13 volts and at least 12.5 volts with the key ‘ON’. Connect a battery charger if
necessary to bring voltage level above minimum. Fully charge the battery before you attempt to reprogram.
• DEDICATED LAPTOP: Best results are obtained using a laptop computer that is “dedicated to Digital Wrench®”. A
laptop that is used by a variety of people and in several applications around the dealership is more likely to cause a
reprogramming problem than one dedicated to Digital Wrench® diagnostics only.
• OBTAINING THE LATEST UPDATE: Reprogramming updates are provided periodically and contain the most recent
calibrations (see Chapter 4 – Digital Wrench® Updates, page 4.46.
• CLOSE NON-ESSENTIAL PROGRAMS: Polaris recommends that you DO NOT install non-essential programs on a
Service Department laptop. Camera detection software, Virus Scanners, Tool Bars, etc. may clog up memory if
running in the background and make it harder for the diagnostic software to operate.
• KNOW THE PROCESS: If you are not familiar with the entire reprogramming process, review the HELP section of
the diagnostic software before you attempt reprogramming. Click on the ? on the tool bar or press F11. The
information in the on-line help is the most current and complete information available. This should be your first step
until you are familiar with the process.
• COMMUNICATION PROBLEMS: If you have had problems communicating with a vehicle while performing
diagnostic functions, do not attempt reprogramming until the cause has been identified and fixed. Check all
connections, and be sure battery voltage is as specified.
FUEL SYSTEM
• Proceed to http://polaris.diagsys.com for specific information and FAQs on how to troubleshoot communication
problems.
• DON’T DISTURB THE PC: While reprogramming is in progress, don’t move the mouse and don’t touch the
keyboard. The process only takes a few minutes, and is best left alone until complete.
Reprogramming (Reflash) Procedure:
If you are not familiar with the reprogramming process, review the “Reprogramming (Reflash) Tips” before you begin.
Follow the on-screen instructions as you progress through the steps. If you encounter a problem, always check the
On-Line help for current tips and information.
1. Verify the most current update has been downloaded and loaded into Digital Wrench®. Digital Wrench Software
Version and Update ID, page
2. Connect SmartLink Module cables to PC and vehicle.
3. Open the Digital Wrench® program.
4. Select the model year, product line and vehicle description by selecting the “Change Vehicle Type” icon.
5. Select the “Special Tests” icon.
FUEL SYSTEM
6. Select “Engine Controller Reprogramming”.
4
7. Select the file you want to load into the ECU then click the “Continue” icon to proceed to the Integrity Check and
obtain a Request Code.
FUEL SYSTEM
8. Copy (CTRL+C) the Request Code that will be required on the dealer website in the next step. DO NOT CLOSE
Digital Wrench® or the Request Code will be invalid. NOTE: All characters are letters; there are no numbers in
a request code.
NOTE
Request Codes and Authorization Keys must be entered EXACTLY as they appear on the screen.
9. Go to www.polarisdealers.com and click on “ReFlash Authorization” from the “Service and Warranty” drop-down
menu.
FUEL SYSTEM
10. Enter or paste the Request Code into the box.
11. Select the same file type from the list that you selected previously while in Digital Wrench®. Enter the VIN along
with the customer’s name and address. When completed, click the Authorize button once to proceed.
FUEL SYSTEM
12. An “Authorization Key” will appear in the upper left corner of the screen. Copy this key exactly as it appears.
13. Enter or paste the Authorization Key in the box located on the Digital Wrench® screen. Click the ‘Continue’ button
and follow instructions provided on the screen to complete reprogramming procedure.
14. At this point the reflash process will begin. Do not touch the vehicle or PC during the process.
FUEL SYSTEM
15. Once the ECU reprogramming procedure is complete, click the ‘Finish’ button on the screen. Verify the reflash was
a success by starting the vehicle.
ETC LEARN PROCEDURE

IMPORTANT
This procedure MUST be performed on the vehicle whenever the ECU is replaced or reflashed or the throttle body is
replaced.
1. After the reflash / ECU replacement / throttle body change, leave the key on (engine not running) for 60 seconds.
Do NOT crank the engine during this time.
2. Turn the key off and wait 3 minutes. During this time, the ECU will write values into memory and then completely
shut down.
3. Turn key back on and start the vehicle. The vehicle should operate normally.
4. If the procedure was interrupted at any time, start back at step 1.
4
FUEL SYSTEM
FUEL SYSTEM TROUBLESHOOTING

The correct position of the throttle body stop screw is POOR IDLE
established and set at the factory. DO NOT remove the Symptom: Idle Too High (If greater than 1300 RPM when
tamper proof cap to adjust the throttle body stop screw engine is warm)
or alter its position in any manner. The stop screw
controls the air flow calibration of the throttle body. • Throttle stop screw tampering
• Throttle cable sticking, improperly adjusted, routed
incorrectly
FUEL STARVATION / LEAN MIXTURE • Failed sensor or disconnected wiring
Symptoms: Hard start or no start, bog, backfire, popping • IAC stuck or inoperative
through intake / exhaust, hesitation, detonation, low • Intake air leak
power, spark plug erosion, engine runs hot, surging, high
idle, idle speed erratic. Symptom: Idle Too Low (if less than 1200 RPM when
engine is warm)
• No fuel in tank
• Restricted tank vent, or routed improperly • Dirty throttle body (damaged or improper air filter)
• Fuel lines or fuel injectors restricted • Plugged air filter
• Fuel pump inoperative • Leaking injector (rich condition)
• Air leak in system • Belt dragging
• Intake air leak (throttle shaft, intake boot, gasket or • Throttle stop screw tampering
grommet) • Failed sensor or disconnected wiring
• Failed sensor or disconnected wiring Symptom: Erratic Idle
• Throttle cable incorrectly adjusted
RICH MIXTURE • Air Leaks, dirty injector
Symptoms: Fouls spark plugs, black, sooty exhaust • TPS damaged or mis-adjusted
smoke, rough idle, poor fuel economy, engine runs • Tight valves
rough/ misses, poor performance, bog, engine loads up, • Belt dragging
backfire. • Dirty air cleaner
• Engine worn
• Air intake restricted (inspect intake duct) • Spark Plug fouled
• Air filter dirty/plugged • Throttle stop screw tampering
• Poor fuel quality (old fuel) • Failed sensor or disconnected wiring
• Fouled spark plug
• TPS setting incorrect
• Injector failure
• Failed sensor or disconnected wiring
• Throttle stop screw tampering
PVT SYSTEM
CHAPTER 5
PVT SYSTEM
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
PVT SYSTEM FASTENER TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
PVT SYSTEM OVERVIEW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
CLUTCHING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
GENERAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
DRIVE CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
DRIVEN CLUTCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
MAINTENANCE / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
OVERHEATING / DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
5
OPERATING IN LOW GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
PVT SYSTEM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
PVT SEALING, GUARD, AND DUCT COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.6
PVT DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.7
PVT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.8
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9
BELT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
PVT BREAK-IN (DRIVE BELT / CLUTCHES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
CLUTCH ALIGNMENT / OFFSET / CENTER DISTANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.11
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.12
325 ENGINE TO TRANSMISSION COUPLER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
DRIVE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
DRIVE CLUTCH ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
SHIFT WEIGHT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
SPIDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.19
ROLLER, PIN, AND THRUST WASHER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.19
BUTTON TO TOWER CLEARANCE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
CLUTCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.20
BUSHING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.22
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24
DRIVEN CLUTCH SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.26
ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.26
CLUTCH DISASSEMBLY / INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.27
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.28
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.29
PVT SYSTEM
GENERAL INFORMATION
SPECIAL TOOLS PVT SYSTEM FASTENER TORQUES
PART TOOL DESCRIPTION ITEM TORQUE VALUE
NUM-
BER Drive Clutch Retaining 45 ft-lbs (61 Nm)
Bolt
PU- Clutch Center to Center Distance Tool
50658-A Drive Clutch Spider 290 ft-lbs (393 Nm)
PA-48595 Clutch Puller Drive Clutch Cover Plate 8 ft-lbs (10 Nm)
9314177 Clutch Holding Wrench Driven Clutch Retaining 38 ft-lbs (51 Nm)
Bolt
2871358- Clutch Holding Fixture
A PVT Inner Cover Phillips- 50 in-lbs (5 Nm)
Head Screws
Drive Clutch Spider Removal and Install
2870341 PVT Inner Cover Hex-
Tool 12 ft-lbs (16 Nm)
Head Screws
2870913 Driven Clutch Puller
PVT Outer Cover Bolts 50 in-lbs (5 Nm)
2870910 Roller Pin Tool
Clutch Bushing
2871226 Replacement Tool Kit
2870386 Piston Pin Puller
PU- Universal Clutch Compressor Tool
50518
Clutch Bushing
2871025 Replacement Tool Kit
2870654 Standard Clutch Alignment Tool
PART SPECIAL SUPPLIES

NUM-
BER
N/A Loctite™ 680
8560054 RTV Silicone Sealer

or http://polaris.service-solutions.com
PVT SYSTEM
PVT SYSTEM OVERVIEW

CLUTCHING CHART GENERAL OPERATION
RANGER ETX WARNING
SHIFT DRIVE All PVT maintenance or repairs should be performed by
ALTITUDE
WEIGHT SPRING a certified Polaris Master Service Dealer (MSD)
Red / technician who has received the proper training and
0-1800 10 RHF understands the procedures outlined in this manual.
Orange
(0-6000) (5632282) Because of the critical nature and precision
Meters (7044321)
balance incorporated into the PVT components, it is
(Feet) Red / absolutely essential that no disassembly or repair
1800-3700 10-40 be made without factory authorized special tools
Orange
(6000 - 12000) (5633331) and service procedures.
(7044321)
RANGER 570 The Polaris Variable Transmission (PVT) consists of
SHIFT DRIVE three major assemblies:
ALTITUDE
WEIGHT SPRING 1) The Drive Clutch
0-1800 25–52G Black 2) The Driven Clutch
Meters (0-6000) (5632409) (7043594) 3) The Drive Belt 5
(Feet) 1800-3700 25-48 Black The internal components of the drive clutch and driven
(6000 - 12000) (5633217) (7043594) clutch control engagement (initial vehicle movement),
clutch upshift and backshift. During vehicle development,
RANGER CREW 570 the PVT system is matched first to the engine power
SHIFT DRIVE curve; then to average riding conditions and the vehicle’s
ALTITUDE intended usage. Therefore, modifications or variations of
WEIGHT SPRING
0-1800 25-52G Black components at random are never recommended. Proper
(0-6000) (5632409) (7043594) clutch setup and careful inspection of existing
Meters components must be the primary objective when
(Feet) 1800-3700 25-48 Black troubleshooting and tuning.
(6000 - 12000) (5633217) (7043594)
PVT SYSTEM
DRIVE CLUTCH OPERATION PVT BREAK-IN (DRIVE BELT / CLUTCHES)

Drive clutches primarily sense engine RPM. The two A proper break-in of the clutches and drive belt will
major components which control its shifting function are ensure a longer life and better performance. Break in the
the shift weights and the coil spring. Whenever engine clutches and drive belt by operating at slower speeds
RPM is increased, centrifugal force is created, causing during the 10 hour break-in period as recommended (see
the shift weights to push against rollers on the moveable Chapter 3 “Engine Break-In Period” for break-in
sheave, which is held open by coil spring preload. When example). Pull only light loads. Avoid aggressive
this force becomes higher than the preload in the spring, acceleration and high speed operation during the break-
the outer sheave moves inward and contacts the drive in period.
belt. This motion pinches the drive belt between the
spinning sheaves and causes it to rotate, which in turn
rotates the driven clutch.
MAINTENANCE / INSPECTION
Under normal use the PVT system will provide years of
At lower RPM, the drive belt rotates low in the drive trouble free operation. Periodic inspection and
clutch sheaves. As engine RPM increases, centrifugal maintenance is required to keep the system operating at
force causes the drive belt to be forced upward on drive peak performance. The following list of items should be
clutch sheaves. inspected and maintained to ensure maximum
performance and service life of PVT components. Refer
DRIVEN CLUTCH OPERATION to the troubleshooting checklist at the end of this chapter
Driven clutches primarily sense torque, opening and for more information.
closing according to the forces applied to it from the drive 1. Belt Tension, Drive to Driven Clutch Alignment/
belt and the transmission input shaft. If the torque Offset, and Belt Inspection.
resistance at the transmission input shaft is greater than
the load from the drive belt, the drive belt is kept at the 2. Drive and Driven Clutch Buttons and Bushings,
outer diameter of the driven clutch sheaves. Drive Clutch Shift Weights and Pins, Drive Clutch
Spider Rollers and Roller Pins, Drive and Driven
As engine RPM and horsepower increase, the load from Clutch Springs.
the drive belt increases, resulting in the belt rotating up
toward the outer diameter of the drive clutch sheaves 3. Sheave Faces. Clean and inspect for wear.
and downward into the sheaves of the driven clutch. This 4. PVT System Sealing. Refer to appropriate
action, which increases the driven clutch speed, is called illustrations on the following pages. The PVT system
upshifting. is air cooled by fins on the drive clutch stationary
Should the throttle setting remain the same, and the sheave. The fins create a low pressure area in the
vehicle is subjected to a heavier load, the drive belt crankcase casting, drawing air into the system
rotates back up toward the outer diameter of the driven through an intake duct. The opening for this intake
clutch and downward into the sheaves of the drive clutch. duct is located at a high point on the vehicle (location
This action, which decreases the driven clutch speed, is varies by model). The intake duct draws fresh air
called backshifting. through a vented cover. All connecting air ducts (as
In situations where loads vary (such as uphill and well as the inner and outer covers) must be properly
downhill), and throttle settings are constant, the drive and sealed to ensure clean air is being used for cooling
driven clutches are continually shifting to maintain the PVT system and also to prevent water and other
optimum engine RPM. At full throttle a perfectly matched contaminants from entering the PVT area. This is
PVT system should hold engine RPM at the peak of the especially critical on units subjected to frequent
power curve. This RPM should be maintained during water fording.
clutch upshift and backshift. In this respect, the PVT
system is similar to a power governor. Rather than vary
throttle position, as a conventional governor does, the
PVT system changes engine load requirements by either
upshifting or backshifting.
PVT SYSTEM
OVERHEATING / DIAGNOSIS
During routine maintenance, or whenever PVT system overheating is evident, it’s important to check the inlet and
outlet ducting for obstructions. Obstructions to air flow through the ducts will significantly increase PVT system
operating temperatures. The vehicle should be operated in Low when plowing or pulling heavy loads, or if extended
low speed operation is anticipated.
CLUTCH DRIVE BELT & COVER RELATED ISSUES: DIAGNOSIS

POSSIBLE CAUSES SOLUTIONS / WHAT TO DO
Loading the vehicle into a truck or tall trailer Shift transmission to Low during loading of the vehicle to prevent
when in high range. belt burning.
Starting out going up a steep incline from a
When starting out on an incline, shift the transmission to Low.
stopped position.
Drive at higher speed or use Low. The use of Low is highly
Driving at low RPM or low ground speed (at
recommended for cooler PVT operating temperatures and longer
approximately 3-7 MPH).
component life.
Warm engine at least 5 min., then with transmission in neutral,
Insufficient engine warm-up when exposed to advance throttle to approx. 1/8 throttle in short bursts, 5 to 7
low ambient temperatures. times. The belt will become more flexible and prevent belt 5
burning.
Slow and easy clutch engagement. Fast, effective use of the throttle for efficient engagement.
Towing/Pushing at low RPM/low ground speed. Use Low only.
Plowing snow, dirt, etc./utility use. Use Low only.
Shift the transmission to Low, carefully use fast, aggressive
Stuck in mud or snow. throttle application to engage clutch. WARNING: Excessive
throttle may cause loss of control and vehicle overturn.
Shift the transmission to Low, carefully use fast, aggressive, brief
Climbing over large objects from a stopped
throttle application to engage clutch. WARNING: Excessive
position.
throttle may cause loss of control and vehicle overturn.
Shift the transmission to neutral. Using the throttle, vary the
engine rpm from idle to full throttle. Repeat several times as
Belt slippage from water or snow ingestion into
required. During this procedure, the throttle should not be held at
the PVT system.
the full position for more than 10 seconds. Clutch seals should be
inspected for damage if repeated leaking occurs.
For inspection of clutch components, please contact your Polaris
Clutch malfunction. dealer. Shift transmission to Low during loading of the vehicle to
prevent belt burning.
Fouled plugs, foreign material in gas tank, fuel lines, or
Poor engine performance.
carburetor. Contact you dealer for further service information.
Low: Heavy pulling, basic operational speeds less than 7 MPH,
riding through rough terrain (swamps, mountains, ect.), low
GENERAL RANGE OPERATION GUIDELINES: ground speeds.
High: High ground speeds, speeds above 7 MPH.
OPERATING IN LOW GEAR NOTE

Low gear is the primary driving gear range. Low should
be used in ALL driving applications except for driving on Using High range for heavy loads, hilly terrain, or in wet,
hard packed level surfaces with light loads. In this cir- muddy conditions will increase the chance of drive belt
cumstance, High range may be used. burning.
PVT SYSTEM
PVT SYSTEM SERVICE

PVT SEALING, GUARD, AND DUCT COMPONENTS
REF DESCRIPTION NOTES

q Outer Clutch Cover
w Clutch Cover Seal
e Inner Clutch Cover
r PVT Intake Duct
t PVT Exhaust Duct
y Drain Plug
u Clamp Torque to 10 ft-lbs (14 Nm)
i Screw Torque to 60 in-lbs (7 Nm)
o Bolt Torque to 24 in-lbs (3 Nm)
PVT SYSTEM
PVT DISASSEMBLY 10. Remove the drive clutch retaining bolt and remove
1. Remove the seats. drive clutch using the Drive Clutch Puller.
2. Disconnect the (-) negative battery terminal.

3. Place transmission in neutral.
4. Raise and support the vehicle.
CAUTION
Serious injury may result if machine tips or falls. Be
sure machine is secure before beginning this service
procedure.
5. Remove the left rear wheel.

6. Remove the eight clutch cover screws and remove
the outer clutch cover from the vehicle.
Drive Clutch Puller PA-48595

5
Drive Clutch Holder 9314177
NOTE
Be sure to use the correct Drive Clutch Puller to prevent
damage to crankshaft.
11. Loosen hose clamp attaching the PVT inlet duct to

the inner clutch cover. Disengage hose from the
inner clutch cover.
7. Mark the drive belt direction of rotation and remove 12. Remove the (8) bolts that retain the inner clutch
drive belt (see “DRIVE BELT - Belt Removal”). cover to the engine and transmission. Remove inner
clutch cover. Make note of cable and hose routings
8. Remove the driven clutch retaining bolt and driven for assembly.
clutch assembly.
9. Install the Drive Clutch Holder.
PVT SYSTEM
PVT ASSEMBLY 11. Install drive clutch onto the engine and torque
1. Inspect inner clutch cover. Replace if cracked or retaining bolt to specification.
damaged.
TORQUE
2. Inspect the seal on the transmission input shaft. Drive Clutch Retaining Bolt:
Replace if damaged.
45 ft-lbs (61 Nm)
3. Remove silicone sealant from the engine case and
inner PVT cover. 12. Install the drive belt noting direction of belt rotation
4. Apply RTV silicone sealant to the back side of the (see “DRIVE BELT - Belt Installation”). If a new belt is
inner clutch cover q to ensure a water tight fit installed, install so numbers can be easily read.
between the engine and inner clutch cover. Both 13. Install a new outer clutch cover seal with the colored
surfaces must be clean to ensure adhesion of the stripe facing the inner clutch cover.
silicone sealant.
14. Reinstall outer clutch cover and secure with screws.
Torque screws to specification.
TORQUE
Outer Clutch Cover Retaining Screws:
50 in-lbs (5 Nm)
15. Install the clutch inlet and outlet ducts and tighten the
hose clamps.
TORQUE
Steel Wheel Nuts:
36 ft-lbs (49 Nm)

5. Install and properly align the inner clutch cover. Be 30 ft-lbs + 90º (41 Nm + 90º)
sure the cables and hose routings are correct.
6. Install the (4) inner clutch cover bolts and washers 16. Reconnect the battery negative (-) cable.
that retain the cover to the engine. Torque bolts to
specification. 17. Install engine service panel and both seats.
TORQUE
Inner Clutch Cover Bolts:
12 ft-lbs (16 Nm)
7. Clean the splines inside the driven clutch and on the

transmission input shaft.
8. Apply a light film of grease to the splines on the
shaft.
9. Install the inner clutch sheave, thrust washers (3)
and, noting clutch sheave orientation, outer clutch
sheave. Torque retaining bolt to specification.
TORQUE
Driven Clutch Retaining Bolt:
38 ft-lbs (51 Nm)
10. Clean the end of the taper on the crankshaft and the
tapered bore inside the drive clutch.
PVT SYSTEM
DRIVE BELT
BELT REMOVAL 6. Remove the belt from the vehicle.
NOTE
Inspect the entire clutch outlet duct when replacing a
drive belt. Remove any debris found in the duct.
1. Remove the (8) screws that retain the outer clutch

cover.
2. Maneuver the outer clutch cover outward to access
the drive belt.
BELT INSPECTION
1. Inspect belt for hour glassing (extreme circular wear
5
in at least one spot and on both sides of the belt).
Hour glassing occurs when the drive train does not
move and the drive clutch engages the belt.
2. Inspect belt for loose cords, missing cogs, cracks,
abrasions, thin spots, or excessive wear. Compare
belt measurements with a new drive belt. Replace if
3. Mark the drive belt direction of rotation so that it can necessary.
be installed in the same direction.
3. Belts with thin spots, burn marks, etc., should be
4. Remove the driven clutch mounting bolt. replaced to eliminate noise, vibration, or erratic PVT
operation. See the Troubleshooting Chart at the end
of this chapter for possible causes.
5. Remove the outer sheave.
PVT SYSTEM
BELT INSTALLATION PVT BREAK-IN (DRIVE BELT / CLUTCHES)

A proper break-in of the clutches and drive belt will
NOTE ensure a longer life and better performance. Break in the
Be sure to install belt in the same direction as it was clutches and drive belt by operating at slower speeds
removed. during the 10 hour break-in period as recommended (see
Chapter 3 “Engine Break-In Period” for break-in
1. Install the belt on the vehicle. example). Pull only light loads. Avoid aggressive
acceleration and high speed operation during the break-
in period.
2. Reinstall the outer sheave.

3. Reinstall the driven clutch mounting bolt. Torque to
specification.
TORQUE
Driven Clutch Mounting Bolt
38 ft-lbs (51.5 Nm)
4. Rotate / spin the driven clutch and belt approximately

5-7 times to properly seat the belt in the driven
clutch.
5. Install the outer clutch cover and (8) screws. Torque
screws to specification.
TORQUE
Outer Clutch Cover Retaining Screws:
50 in-lbs (5 Nm)
PVT SYSTEM
CLUTCH ALIGNMENT / OFFSET / CENTER DISTANCE

INSPECTION NOTE
1. Remove the outer PVT cover, drive belt, drive clutch Images for Reference only. The tool shown should only
and driven clutch as outlined in this chapter. be used to check center to center distance.
The location the tool rests on the shafts may vary.
NOTE
The inner PVT cover does not need to be removed to
check the clutch center to center distance. PU-50658–A
2. Install the Clutch Center Distance Tool onto the HOLE YEAR VEHICLE DESCRIPTION
crankshaft and transmission input shaft. The pictures 1 2012 RZR 570
below show a properly installed tool. 2011-14 RZR 900
2 2014-15 RZR XP 1000
2013 RANGER 900
2014-16 ACE
2015-18 ACE 570
2015-16 RGR ETX
3
2013–18 RZR 570 5
2014–18 RANGER 500/570
2014-18 RANGER 900/1000
2015-18 RZR 900
4
2016-18 RZR 1000
2016–18 ACE 900

Clutch Center Distance Tool 4
PU-50658 or PU-50658-A 3. If the tool fits as shown above, the clutch center to
center distance is correct.
4. If the tool does not fit as shown above, adjustment is
needed.
PVT SYSTEM
ADJUSTMENT 6. With the tool now properly installed, in sequence

1. Remove the Clutch Center Distance tool from the torque the eight engine to transmission coupler bolts
engine and transmission. to specification.
2. Remove the inner PVT Cover.

3. Loosen the eight engine to transmission coupler
bolts q.
TORQUE
Engine To Trans Coupler Bolts:
In Sequence:55 ft-lb (75 Nm)
4. Loosen the two fasteners w securing the rear
transmission isolator to the vehicle frame. 7. Torque the two rear transmission isolator fasteners
e to specification
5. With the engine and transmission mounting

fasteners loose, install the Clutch Center Distance
Tool as shown in the inspection process. 8. Remove the Clutch Center Distance tool and
reassemble the PVT system as outlined in this
Clutch Center Distance Tool chapter.
PU-50658
TORQUE
Rear Trans. Isolator Bolts:
40 ft-lbs (54 Nm)
PVT SYSTEM
325 ENGINE TO TRANSMISSION COUPLER 4. Remove the transmission mount through bolts e and
SERVICE discard.
Disassembly Procedure 5. Using a 12 mm hex drive, turn the take-up nuts r
IMPORTANT mount.
The engine / transmission bracket mounting bolts,
washers and flange nuts must always be discarded
when the nuts are either loosened or removed. Failure
to use new mounting hardware during reassembly may
cause damage to the engine crankcase, mounting
bracket, or transmission mounting ears.

and engine to hold the engine in position.
NOTE
5

Remove the lock nuts y and washers t from the
engine to transmission adapter mounting bolts (3)
and discard.
PVT SYSTEM
Assembly Procedure NOTE

1. Clean the take-up nut r threads and install into the Images for Reference only. The tool shown should only
engine to transmission coupler q by hand. be used to check center to center distance.
2. Insert NEW engine to transmission coupler bolts e The location the tool rests on the shafts may vary.
PU-50658–A
1 2012 RZR 570
2011-14 RZR 900
2 2014-15 RZR XP 1000
2013 RANGER 900
2014-16 ACE
2015-18 ACE 570
2015-16 RGR ETX
3
2013–18 RZR 570
2014–18 RANGER 500/570
2014-18 RANGER 900/1000
3. Install the Clutch Center Distance Tool onto the 2015-18 RZR 900
4
crankshaft and transmission input shaft. The pictures 2016-18 RZR 1000
below show a properly installed tool. 2016–18 ACE 900
i.e. 2015 RZR 900 uses the holes marked with a 4
4. Turn the upper and then lower take up nuts (4)

counterclockwise (4) to no more than the specified
torque. Repeat the step 4 process.
TORQUE
60 in-lbs (6.7 Nm)
IMPORTANT
Do not over-torque the take up nuts. Torque nuts using
the sequence described in step 4. If too much torque is
applied to the take up nuts, the transmission mounting
Clutch Center Distance Tool ears may break.
PU-50658 or PU-50658-A
PVT SYSTEM
5. Fully insert the NEW engine to transmission coupler

bolts e. Install NEW washers t and torque NEW
nuts y to specification.
TORQUE
Engine to Transmission Coupler Nuts:
88 ft-lbs (119 Nm)
6. Reinstall PVT Inner Cover, Driven Clutch, Drive

Clutch and PVT Outer Cover.
PVT SYSTEM
DRIVE CLUTCH SERVICE

DRIVE CLUTCH ASSEMBLY VIEW
REF DESCRIPTION REF DESCRIPTION

Clutch Bolt (Replace if removed)
q 47 ft-lbs (63.5 Nm) s Washers
w Lock Washer d One-Way Bearing (EBS)
e Flat Washer f Bolt

Cover Screws
r g Shift Weight
100 in-lbs (12 Nm)
Nut
t Spring h 25 in-lbs (2.8 Nm)
y Limiter Spacer j Button

Spider
u 210 ft-lbs (284 Nm) k Washer
i Sheave Bushing l Roller
o Bushing 1( Pin
a Spacer
PVT SYSTEM
CLUTCH DISASSEMBLY 5. Remove and inspect the clutch spring. See “Drive
1. Using a permanent marker, mark the cover, spider, Clutch Spring Specifications” for spring inspection.
and moveable and stationary sheaves for reference,
as the cast in X's may not have been in alignment
before disassembly.
6. Remove the limiter spacer w and inspect for wear.

Replace if excessive wear is evident.
2. Mark the stationary sheave and clutch shaft to verify

7. Inspect area on shaft e where bushing rides for 5
wear, galling, nicks, or scratches. Replace clutch
the shaft has not turned in the sheave after assembly if worn or damaged.
tightening the spider during clutch assembly.
3. Remove the (6) cover bolts evenly in a cross pattern
and remove cover plate.
4. Inspect cover bushing q. The outer cover bushing is
manufactured with a Teflon coating. Wear is
determined by the amount of Teflon remaining on the
bushing.
CAUTION
DO NOT reassemble the drive clutch without the limiter
spacer w. Belt life will be greatly reduced.
Cover Bushing Inspection:

Replace the cover bushing if more brass than Teflon is
visible on the bushing. Refer to bushing replacement in
this chapter.
PVT SYSTEM
Drive Clutch Spring Inspection SHIFT WEIGHT INSPECTION

1. Remove shift weight bolts and weights. Inspect the
CAUTION
contact surface of the weight q. The surface should
Never shim a drive clutch spring to increase its be smooth and free of dents or gall marks. Inspect
compression rate. This may result in complete stacking the weight pivot bore and bolts w for wear or galling.
of the coils and subsequent clutch cover failure. If weights or bolts are worn or broken, replace in sets
of three with new bolts and nuts.
The drive clutch spring is one of the most critical
components of the PVT system. It is also one of the WARNING
easiest to service. Due to the severe relaxation the The clutch assembly is a precisely balanced unit. Never
spring is subject to during operation, it should always replace parts with used parts from another clutch
be inspected for tolerance limits during any clutch assembly!
operation diagnosis or repair.
With the spring resting on a flat surface, measure its
free length from the outer coil surfaces. Also check to
see that spring coils are parallel to one another.
Distortion of the spring indicates stress fatigue,
requiring replacement.
Drive Clutch Spring Specifications
COLOR FREE LENGTH
Red / Orange 2.54 (64.52 mm)
Black 2.8” (71.12 mm)
NOTE
A damaged shift weight is usually caused by a
damaged or stuck roller in the spider assembly. See
“Roller, Pin and Thrust Washer Inspection”.
PVT SYSTEM
SPIDER REMOVAL Moveable Sheave Bushing Inspection

1. Install clutch in holding fixture q and loosen the 2. Inspect the Teflon™ coating on the moveable sheave
spider (counterclockwise) using Clutch Spider bushing.
Removal Tool w.
Clutch Holding Fixture:

Moveable Sheave Bushing Inspection:
Replace the cover bushing if more brass than Teflon is
5
PN 2871358-A visible on the bushing. Refer to bushing replacement in
this chapter.
Spider Removal Tool:
PN 2870341
ROLLER, PIN, AND THRUST WASHER
NOTE INSPECTION
It is important that the same number and thickness of 1. Inspect all rollers, bushings and roller pins by pulling
washers are reinstalled beneath the spider during a flat metal rod across the roller. Turn roller with your
assembly. Be sure to note the number and thickness of finger. If you notice resistance, galling, or flat spots,
these washers. replace rollers, pins and thrust washers in sets of
three. Also inspect to see if roller and bushing are
separating. Bushing must fit tightly in roller. Use the
Roller Pin Tool to replace rollers and pins. Take care
not to damage roller bushing or bearing surface of
the new pin during installation.
Roller Pin Tool:

PN 2870910
PVT SYSTEM
2. Rubber backed buttons can be used in all RANGER BEARING INSPECTION

clutches if the hollow roller pin is changed to the solid 1. Rotate the clutch bearing in both clockwise and
roller pin. counter-clockwise directions.
NOTE • The non-braking bearing should rotate both directions
on the shaft with only a slight amount of drag.
The rubber side of the button is positioned toward the
solid roller pin. 2. Verify there is no binding or rough spots. If problems
are noted continue with disassembly.
BUTTON TO TOWER CLEARANCE CLUTCH INSPECTION

INSPECTION
NOTE
1. Inspect for any clearance between spider button to
tower. If clearance exists, replace all buttons and Remove cover, spring, and spider following instructions
inspect surface of towers. See “Spider Removal” for drive clutch removal, then proceed as follows:
procedure.
1. Remove the moveable sheave spacer sleeve q.
Inspect for damage and wear.
Button to Tower Clearance:

.000-.010”
2. Inspect sheave surfaces. Replace the entire clutch if

worn, damaged or cracked.
PVT SYSTEM
2. Remove the moveable clutch sheave w. Inspect for 4. Inspect surface of shaft for pitting, grooves, or
damage and wear. damage. Measure the outside diameter and
compare to specifications. Replace the drive clutch
assembly if shaft is worn or damaged.
3. Lift bearing e and thrust washers r off shaft.

Replace as an assembly if worn, damaged, or if
problems were noted.
MEASUREMENT 5
Shaft Diameter:
Standard: 1.3745” - 1.375” (34.91 - 34.93 mm)
Service Limit: 1.3730” (34.87 mm)
5. Visually inspect PTFE thrust washers for damage.

Measure the thickness and compare to specification.
Replace if worn or damaged.
MEASUREMENT
PTFE Washer Thickness
Standard: .030” (.76 mm)
Service Limit: .025” (.64 mm)
PVT SYSTEM
BUSHING SERVICE NOTE

NOTE Bushings are installed at the factory using Loctite™
609. In order to remove bushings it will be necessary to
Special Tools Required apply heat evenly to the area around each bushing.
Clean all residual Loctite™ from bushing bore prior to
installing new bushing.
Additional Special Tools
QT-
PART DESCRIPTION
PAR- CAUTION
Y. T#
Clutch components will be hot! In order to avoid serious
2871- burns, wear insulated gloves during the removal
1 Clutch Bushing Replacement Tool Kit
226 process.
2870-
1 Piston Pin Puller Moveable Sheave - Bushing Removal
386
1. Remove clutch as outlined previously in this chapter.
*Clutch Bushing Replacement Tool Kit (PN 2871226)
2. Install handle end of the Piston Pin Puller securely
IT- QT- PAR- into bench vise and lightly grease puller threads.
PART DESCRIPTION
EM Y. T#
Piston Pin Puller:
P-90 Drive/Driven Clutch Bushing 5020-
#2 1 PN 2870386
Install Tool 628
Drive Clutch Cover Bushing 3. Remove nut from puller rod and set aside.
Removal/Installation Tool (all 5020-
#3 1
clutches) 629
P-90 Driven Clutch Cover Bushing 5020-

#5 1
Removal Tool 631
Main Puller Adapter 5020-

#8 1
632
Adapter Reducer 5010-

#9 1
279
Number Two Puller Adapter 5020-

#10 1
633
4. Install puller adapter (Item 10 from kit).

Puller Adapter:
PN 2871226
PVT SYSTEM
5. Install main adapter (Item D) onto puller. 13. Thoroughly clean bushing bore
14. Apply Loctite™ 609 evenly to bushing bore inside
moveable sheave.
15. Set bushing in place on sheave.
16. Insert installation puller tool (Item A/B) with “A” side
down, into center of bushing.
17. With towers pointing upward, slide sheave, bushing
and tool onto puller rod.
18. Install nut on puller rod and hand tighten. Turn barrel
to apply additional tension if needed.
19. Turn sheave counterclockwise, making sure bushing
is drawn straight into bore. Continue until bushing is
seated.
20. Remove nut from puller rod and set aside.
21. Remove sheave from puller.
6. With towers pointing toward the vise, slide sheave
22. Remove installation tool.
onto puller rod.
Cover Bushing Removal
5
7. Install removal tool (Item A, B) into center of sheave
with “A side" toward sheave. 23. Install main adapter (Item 8) on puller.
NOTE
Use Bushing Tool PA-47336.
8. Install nut (C) onto end of puller rod and hand

tighten. Turn puller barrel to increase tension on
sheave if needed. Using a hand held propane torch,
apply heat around outside of bushing until tiny
smoke tailings appear.
9. Turn sheave counterclockwise on puller rod until it
comes free. Lift sheave off puller.
11. Pull bushing removal tool and adapter from puller
rod. Remove bushing from tool and discard.
Drive Clutch Bushing Installation
12. Place main adapter (Item 8) on puller. 24. Install adapter reducer (Item 9).
25. From outside of clutch cover, insert removal tool
(Item 3) into cover bushing.
26. With inside of cover toward vise, slide cover onto
puller.
27. Install nut onto puller rod and hand tighten. Turn
puller barrel to increase tension as needed.
28. Turn clutch cover counterclockwise on puller rod until
bushing is removed and cover comes free.
30. Remove bushing and bushing removal tool from
puller. Discard bushing.
Cover Bushing Installation
31. Apply Loctite™ 609 evenly to bushing bore in cover.
PVT SYSTEM
32. Working from inside of cover, insert new bushing and CLUTCH ASSEMBLY
bushing installation tool into center of clutch cover.
NOTE
33. With main adapter on puller, insert cover onto puller
rod, placing outside of cover toward vise. The Teflon bushings are self-lubricating.
34. Install nut on rod and hand tighten. Turn puller barrel
to apply more tension if needed. CAUTION
35. Turn clutch cover counterclockwise on puller rod until Do not apply oil or grease to the bushings.
bushing is seated.
36. Remove nut from puller rod. Take installation tool Reassemble the drive clutch in the following sequence.
and clutch cover off rod. Be sure the “X”, or the marks that were made earlier are
aligned during each phase of assembly.
1. Install the PTFE washers e and non braking bearing

r over the clutch shaft. There should be one fiber
washer on each side of the bearing.
2. Install the moveable sheave and spacer w onto the
clutch shaft.
NOTE
To maintain proper clutch balance and belt-to-sheave
clearance. be sure to reinstall the original quantity and
thickness of washers / spacers beneath the spider
during assembly.
PVT SYSTEM
3. Compress spider buttons for each tower and install

spider q, making sure that “X”, or the marks that
were made earlier, on spider aligns with “X”, or the
marks that were made earlier, in moveable sheave.
4. Torque spider to specification using the holding
fixture and spider tool. Torque with smooth motion to
avoid damage to the stationary sheave.
TORQUE
Drive Clutch Spider:
290 ft-lbs (393 Nm)
5. Install shift weights using new lock nuts t on the

bolts.
6. Reinstall clutch spring.

7. Reinstall cover, aligning “X” mark with other marks.
8. Torque cover bolts evenly to specification.
TORQUE
Drive Clutch Cover Screw:
8 ft-lbs (10 Nm)
PVT SYSTEM
DRIVEN CLUTCH SERVICE

ASSEMBLY VIEW
q Subassembly, Stationary Boss u Cup, Spring Boss
w Roller, Clutch i Plate, Retainer

Screw
e Washer, Thrust o 9 ft-lbs (12 Nm)
r Ring, Retaining E-Ring External a Label, Clutch Boss
t Subassembly, Moveable Boss s Washer, Thrust
y Spring, Compression
PVT SYSTEM
CLUTCH DISASSEMBLY / INSPECTION 8. Remove the compressor tool from the clutch
assembly.
CAUTION
9. Remove the spring retainer (A), spring cup (B),
Hold outer sheave securely to relieve spring spring (C) and washer (D - early build only) from the
pressure while removing the retaining bolt. inner clutch sheave (E).
1. Mark the position of the clutch sheaves before clutch

removal or use the X’s on the sheaves for reference.
This aids in reassembly and maintains clutch
balance after reassembly.
5
10. Check the rollers in the stationary sheave for wear. If
rollers are worn, a new driven clutch assembly may
be needed.
11. Inspect the bearings inside the moveable sheave.
2. Remove the drive belt ().
12. Inspect driven clutch sheave faces for wear or
3. Remove the clutch retaining bolt and washer. damage.
4. Remove outer clutch sheave, thrust washers (3) and 13. Clean and inspect splines on helix and transmission
inner clutch sheave. input shaft.
5. Reassemble the clutch sheaves and place the driven 14. Lube splines with a light film of grease. Do not
clutch into a universal clutch compressor. Spin the lubricate the bearings!
tool down until it touches the spring cup.
6. Using a T30 Torx driver, remove the five screws that

secure the spring retainer to the inner clutch sheave.
7. Turn the compression tool handle counter-clockwise
to relieve spring pressure and allow the spring cup
and retaining ring to move out from the moveable
sheave.
PVT SYSTEM
CLUTCH ASSEMBLY
1. Align the “X” marks on each of the sheaves during
reassembly.
2. Assemble the clutch sheaves
3. Position the spring washer, spring, spring cup and

retaining ring into moveable sheave. Do not apply oil
or grease to the bearings.
4. Place the clutch into the universal clutch compressor.
Apply and hold downward pressure on the spring
cup. Torque the retaining ring bolts to specification.
TORQUE
Clutch Spring Retaining Ring Bolts:
12 ft-lbs (16 Nm)
5. Install driven clutch assembly and drive belt.
PVT SYSTEM
TROUBLESHOOTING
SITUATION PROBABLE CAUSE REMEDY

-Wrong or broken drive clutch spring. -Replace with recommended spring.
Engine RPM
below specified -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine
operating range, application.
although engine -Driven clutch spring broken or installed in
is properly tuned. wrong helix location. -Replace spring; refer to proper installation
location.
-Drive clutch binding. A. Disassemble drive clutch; inspect shift
weights for wear and free operation.
B. Clean and polish stationary shaft hub;
reassemble clutch without spring to determine
Erratic engine problem area.
operating RPM
during -Belt worn unevenly - thin / burnt spots. Replace belt.
acceleration or
load variations. -Driven clutch malfunction. A. Replace ramp buttons.
B. Inspect movable sheave for excessive 5
bushing clearance.
-Sheave face grooved. -Replace the clutch.

-Incorrect drive clutch spring (too high spring -Install correct recommended spring.
rate).
-Drive clutch shift weights incorrect for -Install correct recommended shift weights.
application (too light).
-Drive clutch binding. -Disassemble and clean clutch, inspecting shift
weights and rollers. Reassemble without the
Engine RPM spring and move sheaves through entire range
above specified to further determine probable cause.
operating range.
-Driven clutch binding. -Disassemble, clean, and inspect driven clutch,
noting worn sheave bushing and ramp buttons
and helix spring location.
-Converter sheaves greasy; belt slippage. -Clean sheaves with denatured alcohol or brake
cleaner, install new belt.
-Drive belt worn too narrow. -Replace belt.
Harsh drive clutch
engagement. -Excessive belt / sheave clearance with new -Perform belt / sheave clearance adjustment
belt. with shim washers beneath spider.
-Wrong belt for application. -Replace with correct belt.
Drive belt turns -Clutch alignment out of spec. -Adjust alignment offset.
over
-Engine mount broken or loose. -Inspect / adjust or replace.
-Abuse (continued throttle application when -Caution operator to operate machine within
vehicle is stationary, excess load) guidelines.
Belt burnt, thin -Dragging brake -Vehicle operated with park brake on. Inspect
spots brake system.
-Slow, easy clutch engagement
-Fast, effective use of throttle for efficient
engagement.
PVT SYSTEM
-Plugged air intake or outlet. -Clear obstruction
-Belt slippage due to water, oil, grease, etc., -Inspect system. Clean , repair or replace as
rubbing on cover.-Clutches or weight being necessary.
PVT cover applied to cover while in operation. Seal PVT system ducts.
overheating
(melting) -High vs. low range. -Remove weight. Inform operator.
-Instruct operator on guidelines for operation in

proper driving range for different terrain as
outlined in Owner’s Safety and Maintenance
Manual.
-Cover seals or ducts leaking -Find leak and repair as necessary.
Water ingestion -Operator error -Instruct operator on guidelines for operation in

wet terrain as outlined in Owner’s Safety and
Maintenance Manual.
-Belt worn out -Replace belt.
Belt slippage -Water ingestion -Inspect and seal PVT system.
-Belt contaminated with oil or grease -Inspect and clean.

-Belt worn or separated, thin spots, loose -Replace belt.
PVT noise belt-Broken or worn clutch components, -Inspect and repair as necessary.
cover hitting clutches
-Replace belt. Refer to belt burnt troubleshooting
Engagement -Thin spots on belt, worn belt
and instruct operator.
erratic or stabby -Drive clutch bushings stick
-Inspect and repair clutches.
TRANSMISSION
CHAPTER 6
TRANSMISSION
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SPECIAL TOOLS, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3
TRANSMISSION GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
TRANSMISSION MOUNTING AND TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
SHIFT LEVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.5
SHIFT CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.6
TRANSMISSION REMOVAL - 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.7 6
TRANSMISSION REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10
TRANSMISSION INSTALLATION - 325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.12
TRANSMISSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.15
TRANSMISSION SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.18
DIFFERENTIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.18
TRANSMISSION DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.19
PLANETARY DIFFERENTIAL DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.24
PLANETARY DIFFERENTIAL BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.24
PLANETARY DIFFERENTIAL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.26
GEAR / SHAFT / BEARING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.27
SNORKEL GEAR BACKLASH PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.28
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.35
TROUBLESHOOTING CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.35
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.36
TRANSMISSION ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.36
TRANSMISSION
GENERAL INFORMATION
TORQUE SPECIFICATIONS
ITEM TORQUE VALUE
Bell Crank Nut 15 ft-lbs (20 Nm)
Differential Cover Screws 22 ft-lbs (30 Nm)

Park Flange Screws 8 ft-lbs (11 Nm)
Sector Gear Cover 11 ft-lbs (15 Nm)
Shift Cable Bracket Bolts 37 ft-lbs (50 Nm)
Shift Fork Screws 10 ft-lbs (14 Nm)

Snorkel Bearing Retaining Plate Screws 8 ft-lbs (11 Nm)
Snorkel Tube Locking Screw 8 ft-lbs (11 Nm)
Speed Sensor Screw 10 ft-lbs (14 Nm)
Transmission Case Screws 18 ft-lbs (24 Nm)

Transmission Fill / Drain Plugs 14 ft-lbs (19 Nm)
Transmission Rear Isolator Bolt 40 ft-lbs (54 Nm)
Transmission Rear Mount Bracket Fasteners 17 ft-lbs (23 Nm)
SPECIAL TOOLS, TRANSMISSION

PA-50231 Snorkel Tool
2871698 (Part of
Rear Output Seal Driver
2871702 Kit)
2871699 (Part of
2871702 Kit) Rear Driveshaft Seal Guide
2871282 Bearing Seal Driver (50 mm)

PU-50566 Transmission Nut Socket
PU-50658 Clutch Center Distance Tool
Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/
TRANSMISSION
SPECIAL TOOLS
TRANSMISSION
TRANSMISSION GEARS LUBRICATION

Please refer to the Polaris Parts Catalog for gear tooth
counts and part numbers. FLUID CAPACITY
To access the Polaris Parts catalog please visit: AGL (PN 2878068) (Quart)
Capacity: 41 oz. (1200 ml)
http://parts.polarisind.com/browse/browse.asp
TRANSMISSION MOUNTING AND TORQUE VALUES

q Bolt Torque to 55 ft-lbs (75 Nm)
w Bolt Torque to 40 ft-lbs (54 Nm)
e Bolt Torque to 25 ft-lbs (34 Nm)
TRANSMISSION
SHIFT LEVER
REMOVAL 4. Remove the retaining ring i and slide the shift lever
1. Remove the shift knob cover q , retaining screw w off the mounting bracket and out from the frame.
and shift knob e from the shift lever r.
5. Remove both bushings o from the shift lever and

2. Remove the screws retaining the center console service as needed.
using a T27 and T30 Torx driver. Remove the
console from the vehicle. INSTALLATION
3. Remove the clip t and washer y retaining the shift 1. Perform the removal steps in reverse order to install
cable u to the shift lever and disconnect the cable the gear shift lever (lever, cable, console, shift knob) 6
end from the lever.
TRANSMISSION
SHIFT CABLE
INSPECTION
Shift cable adjustment may be necessary if symptoms
include:
• No gear position display on instrument cluster
• Inability to engage into or stay in a gear
• Excessive gear lash (noise)
Inspect shift cable, clevis pins, and pivot bushings and
replace if worn or damaged.
ADJUSTMENT
1. Locate the shift cable attached to the transmission
case in the right rear wheel well area.
2. Inspect shift cable, clevis pin, pivot bushings, and
dust boot. Replace if worn or damaged.
3. If adjustment is required, loosen the lower jam nut q
and pull the cable out of the mount to move the
upper jam nut w.
4. Adjust the shift cable so there is the same amount of

cable travel when shifting slightly past HIGH gear
and PARK.
5. Thread the upper or lower jam nut as required to
obtain proper cable adjustment.
NOTE
This procedure may require a few attempts to obtain
the proper adjustment.
6. Once the proper adjustment is obtained, place the

shift cable and upper jam nut into the mount. Tighten
the lower jam nut against the mount.
7. Start engine and shift through all gears to ensure the
shift cable is properly adjusted. If transmission still
ratchets after cable adjustment, the transmission will
require service.
TRANSMISSION
TRANSMISSION REMOVAL - 325

1. Remove the cargo box and seat (see Chapter 5).
battery.
4. Remove the propshaft from the transmission output
shaft (see Chapter 7).
5. Remove rear wheels from the vehicle.

6
6. If internal transmission repair is required, drain the
transmission lubricant (see Chapter 2).
7. Remove the breather hose (Item 2), loosen the air

intake duct clamps (Item 3), remove the duct
mounting bolt (Item 4) and remove the intake duct
(Item 5).
TRANSMISSION
8. Disconnect the main harness from the IAC and TPS NOTE
at the throttle body.
9. Loosen the air box to throttle body clamp (Item 6) and
move the air box assembly (Item 7) out of the way
towards the driver’s seat. 13. Remove vent hose from transmission.
14. Remove the gear position switch connector (Item 8),
speed sensor connector (Item 9), crankshaft position
sensor connector, shift bracket bolts (Item 10) and
shift bracket (Item 11), shift cable clevis pin and
washer (Item 12) from the transmission.

NOTE
Be sure to use the correct Drive Clutch Puller (PA- 15. Remove the wire ties retaining the main harness
48595) to prevent damage to crankshaft. harness to transmission and mounts.
16. Remove the lock nuts and washers from the engine
11. Remove driveshaft from both sides (see Chapter 7). to transmission coupler mounting bolts.
and engine to hold the engine up in position.
TRANSMISSION

bolts and discard.
18. Using a 12 mm hex drive, turn the take-up nuts (3)
mount.
19. Remove the two bolts attaching the rear transmission

mount bracket assembly to the frame. Remove the
bolt that attaches the rear mount to the transmission.
Remove the mount assemblies from the vehicle.
20. Using an overhead lift or an assistant, lift the
transmission up and out of the chassis.
TRANSMISSION
TRANSMISSION REMOVAL
CAUTION 8. Remove the breather hose (Item 2), loosen the air
intake duct clamps (Item 3), remove the duct
Serious injury may result if machine tips or falls. Be mounting bolt (Item 4) and remove the intake duct
sure machine is secure before beginning this (Item 5).
procedure. Always wear eye protection.
1. Remove the cargo box and seat (see Chapter 5).

battery.
4. Remove the propshaft from the transmission output
9. Disconnect the main harness from the IAC and TPS

at the throttle body.
10. Loosen the air box to throttle body clamp (Item 6)
and move the air box assembly (Item 7) out of the
way towards the driver’s seat..
5. Remove rear wheels from the vehicle.

6. If internal transmission repair is required, drain the
transmission lubricant (see Chapter 2).
7. Remove the air box mounting bolt (Item 1).

NOTE
Be sure to use the correct Drive Clutch Puller (PA-
12. Remove driveshaft from both sides (see Chapter 7).
TRANSMISSION
13. Place a spacer or support between the vehicle frame 17. Using a 15mm socket, remove the four bolts (Item
and engine to hold the engine up in position. 13) from the coupler securing the transmission to the
engine.
14. Remove vent hose from transmission.

18. Remove the two bolts (Item 14) attaching the rear
15. Remove the gear position switch connector (Item 8),
transmission mount bracket assembly to the frame.
speed sensor connector (Item 9), crankshaft position
Remove the bolt (Item 15) that attaches the rear
sensor connector, shift bracket bolts (Item 10) and
mount to the transmission. Remove the mount
shift bracket (Item 11), shift cable clevis pin and
assemblies from the vehicle.
washer (Item 12) from the transmission.
19. Using an overhead lift or an assistant, lift the
transmission up and out of the chassis. 6
16. Remove the wire ties retaining the main harness

harness to transmission and mounts.
TRANSMISSION
TRANSMISSION INSTALLATION - 325

1. With the help of an assistant, position the TORQUE
transmission into the vehicle frame through the top.
Rear Transmission Mount Bracket Bolts:
2. Install the rear transmission mount assemblies. 17 ft-lbs (23 Nm)
Torque all fasteners to specification.
3. Clean the take-up nut threads and install into the

engine to transmission coupler by hand.
4. Insert NEW engine to transmission coupler bolts (3)
REF.DESCRIPTION NOTES
q Fastener Bolt Torque to 40 ft-lbs (54
Nm)
w Fastener Bolt Torque to 25 ft-lbs (34
Nm)
5. Install the Clutch Center Distance Tool (PU-50658)
onto the crankshaft and transmission input shaft to
establish the clutch center distance.
6. Torque the upper, then lower engine to transmission

adapter take up nuts (4) counterclockwise to
specification. Repeat the Step 7 process.
TRANSMISSION
TORQUE TORQUE
Engine to Transmission Coupler Take Up Nut: Shift Cable Bracket Bolts:
60 in-lbs (6.7 Nm) 37 ft-lbs (50 Nm)
7. Fully insert the NEW engine to transmission coupler 11. Install three wire ties to retain wire harness to
bolts (3). Install NEW washers (5) and torque NEW transmission and mounts.
nuts (6) to specification. 12. Install and properly route the vent hose.
TORQUE 13. Lubricate the transmission splines and mid prop shaft
joint splines with Polaris All Purpose Grease. Install
Engine to Transmission Coupler Nuts: the prop shaft onto the transmission output shaft (see
88 ft-lbs (119 Nm) Chapter 7).
14. Install inner clutch cover, outlet duct, drive clutch,
8. Remove the lifting straps and overhead or portable driven clutch, belt and outer clutch cover (see
engine hoist and remove the spacer blocks previously Chapter 6).
installed under the transmission and engine. 15. Install new spring ring (Item 13) on rear drive shafts.
9. Install and properly route the gear position switch Apply an anti-seize compound to the splines (Item
connector (Item 8), speed sensor connector (Item 9), 14).
crankshaft position sensor connector, shift bracket
bolts (Item 10), shift bracket (Item 11), shift cable
clevis pin and washer (Item 12) onto the
transmission.
16. Reinstall the driveshafts into the bearing carriers and

fasten the bearing carriers to the control arms. Torque
fasteners to specification.
10. Torque the (2) shift cable bracket bolts to TORQUE
specification.
Bearing Carrier Fasteners:
40 ft-lbs (54 Nm)
17. Install rear wheels and wheel nuts. Torque to

specification.
TORQUE
Steel Wheel Nuts:
36 ft-lbs (49 Nm)
30 ft-lbs + 90º (41 Nm + 90º)
18. Properly lower the vehicle

19. Install cone washers and castle nuts for the
driveshafts. Torque to specification.
TRANSMISSION
TORQUE
Castle Nut:
110 ft-lbs (150 Nm)
20. Install a new cotter pin into each castle nut and install
the caps.
21. Install the throttle body, air box assembly and ducting.
22. Reconnect the TPS and IAC harnesses.
23. Connect the (-) negative battery cable and reinstall
the seat base.
24. Reinstall the cargo box.
25. If transmission lubricant was drained, fill the
transmission with the specified amount of Polaris
AGL (see Chapter 2 “Transmission Lubrication”).
FLUID CAPACITY
AGL (PN 2878068) (Quart)
Capacity : 41 oz. (1200 ml)
TRANSMISSION
TRANSMISSION INSTALLATION
1. With the help of an assistant, position the 4. Install the Clutch Center Distance Tool (PU-50658)
transmission into the vehicle frame through the top. onto the crankshaft and transmission input shaft to
properly position the clutch center distance. The
2. Install the rear transmission mount assemblies.
pictures below show the tool (PU-50658) properly
Torque all fasteners to specification.
installed.

q Fastener Bolt Torque: 40 ft-lbs
(54 Nm) 6
w Fastener Bolt Torque: 25 ft-lbs
(34 Nm)
TORQUE
Rear Transmission Mount Bracket Bolts:
17 ft-lbs (23 Nm)
3. By hand, install the coupler brackets and the eight

engine to transmission coupler bolts. Do not torque
fasteners at this time.
TRANSMISSION
5. In sequence, torque the eight engine coupler bracket 8. Install and properly route the gear position switch
fasteners to specification. connector (Item 8), speed sensor connector (Item 9),
crankshaft position sensor connector, shift bracket
TORQUE bolts (Item 10), shift bracket (Item 11), shift cable
Engine to Trans Coupler Fasteners clevis pin and washer (Item 12) onto the
In Sequence:55 ft-lb (75 Nm) transmission.
9. Torque the (2) shift cable bracket bolts to

specification.
6. Remove the clutch center distance tool.
7. Remove the spacer or support between the vehicle TORQUE
frame and engine. Shift Cable Bracket Bolts:
37 ft-lbs (50 Nm)
10. Install three wire ties to retain wire harness to

transmission and mounts.
11. Install and properly route the vent hose.
12. Lubricate the transmission splines and mid prop
shaft joint splines with Polaris All Purpose Grease.
Install the prop shaft onto the transmission output
13. Install inner clutch cover, outlet duct, drive clutch,
driven clutch, belt and outer clutch cover (see
Chapter 6).
14. Install new spring ring (Item 13) on rear drive shafts.
Apply an anti-seize compound to the splines (Item
14).
TRANSMISSION
15. Reinstall the driveshafts into the bearing carriers and

fasten the bearing carriers to the control arms.
Torque fasteners to specification.
TORQUE
40 ft-lbs (54 Nm)
16. Install rear wheels and wheel nuts. Torque to

specification.
TORQUE
Steel Wheel Nuts:
36 ft-lbs (49 Nm)

30 ft-lbs + 90º (41 Nm + 90º)
17. Properly lower the vehicle.

18. Install cone washers and castle nuts for the
driveshafts. Torque to specification.
TORQUE
Castle Nut110 ft-lbs (150 Nm) 6
19. Install a new cotter pin into each castle nut and
install the caps.
20. Install the throttle body, air box assembly and
ducting.
21. Reconnect the TPS and IAC harnesses.
22. Connect the (-) negative battery cable and reinstall
the seat base.
23. Reinstall the cargo box.
24. If transmission lubricant was drained, fill the
transmission with the specified amount of Polaris
AGL (see Chapter 2 “Transmission Lubrication”).
FLUID CAPACITY
AGL (PN 2878068) (Quart)
Capacity : 41 oz. (1200 ml)
TRANSMISSION
TRANSMISSION SERVICE
DIFFERENTIAL OPERATION extends out to move the fork and slides the engagement
The transmission has two traction operational modes: dog away from the side gear that is part of the planetary
Differential Lock and Differential Unlock. Locking the rear differential assembly. This unlocks the rear differential.
differential is beneficial in low traction and rough terrain The rear drive shafts are now dependent on the
conditions. Unlocking the rear differential makes differential allowing for tighter turns.
maneuvering easier and minimizes damage to terrain.
When “Differential-Lock” is selected, power is removed

from the electrical solenoid allowing the solenoid plunger
to retract. Spring tension moves the shift fork back into
place and mates the engagement dog to the side gear
When “Differential-Unlock” is selected, the rear that is part of the planetary differential assembly. This
differential becomes unlocked for tighter turns. An locks the rear differential as a solid rear axle, increasing
electrical solenoid mounted in the rear portion of the traction.
gearcase actuates the shift fork. The solenoid plunger
TRANSMISSION
TRANSMISSION DISASSEMBLY 6. Remove the compression spring (H).
NOTE
Refer to the exploded view at the end of this chapter as
a reference.
1. Place transmission in High gear before disassembly.

2. Drain and properly dispose of the transmission
lubricant (see Chapter 2).
3. Remove the bell crank nut (A) and bell crank (B).
7. Remove the detent star (I). Note how the detent star
fits onto the splined shaft with the raised edge facing
outward for reassembly.
8. Remove the spacer (J).
9. Remove the shift shaft (K), detent pawl (L) and the 6
shift sector gears (M and N).
NOTE
Note the timing marks on the shift gears (M and N) for
reassembly purposes.
4. Remove E-clip (C) that retains spring washer (D), flat 10. Remove the O-rings (P) from each shaft and discard.
washer (D) and gear switch (E). Remove the switch. Use new O-rings upon assembly.
5. Remove the sector cover bolts (F) and remove the
sector cover (G).
NOTE
Removal can be aided by using your thumbs to press in
on the shafts while pulling out the cover with your
fingers.
TRANSMISSION
11. Remove all transmission case bolts. Using suitable 13. Remove the shift shaft rail (Q) and shift forks from
pry bars, remove the cover using the designated pry the transmission housing as an assembly.
points (indicated by black arrows in illustration
below).
14. Remove the rear output shaft assembly (S) by lifting

underneath the gear or by tapping the shaft from the
opposite side. If use of a pry bar is necessary, take
care not to pry on sealing surfaces of case.
CAUTION
Do not pry on case sealing surfaces. Use only the
designated pry points on the transmission.
12. Lift up on the shift shaft rail (Q) and move the rail
assembly rearward to allow the shift fork pins to be
removed from the shift drum (R). Remove the shift
drum (R) from the transmission housing.
TRANSMISSION
15. Remove the idler gear shaft assembly (T) and gear 19. Using a 5 mm Allen wrench, remove the screws that
cluster assembly (U) from the transmission housing secure the pinion shaft assembly (V). Lift the pinion
by pulling both assemblies straight up. shaft assembly straight up to remove it from the
housing. Note the longer screw (W) that locks the
snorkel tube.
16. Place the idler gear shaft assembly (T) and gear
cluster assembly (U) on a clean surface for
inspection. If disassembly is required, refer to “Gear 20. Remove all seals from the gearcase halves and
Cluster Disassembly”. clean the cases in preparation for assembly.
Gear Cluster Disassembly
17. Slide engagement dog (X) off of shift fork guides. 6
18. Remove two screws and retaining plates, then lift 21. Remove the bearing from the reverse shaft using a
shift fork (Y) and torsion spring out of transmission bearing puller. Remove the retaining ring and slide
housing. the washers, 53T gear and needle bearing off the
reverse shaft (see Figure 8-1).
22. Remove the retaining ring and engagement dog from

the reverse shaft (see Figure 8-1).
TRANSMISSION
23. Remove the retaining ring, washer, needle bearing, Snorkel Shaft Removal / Disassembly
and sprocket from the reverse shaft (see Figure 8-1).
CAUTION
24. Tilt the two shafts towards each other and remove
the silent chain from the two shafts. The pinion shaft must be removed prior to removing the
snorkel shaft assembly. Failure to remove pinion shaft,
25. If necessary, disassemble the other end of the will result in damage to the snorkel shaft.
reverse shaft. Remove the bearing, engagement
dog, retaining ring, washer, gear and needle bearing 27. Extract the seal from the snorkel shaft to access the
from the reverse shaft (see Figure 8-2). snorkel tube for removal.
28. Using the Snorkel Tool (PA-50231), fully loosen the

snorkel tube.
26. To disassemble the shift shaft rail remove the snap
ring (X) from the end of the shift rail on either side.
CAUTION
Use caution when disassembling the shift rail. The
compressed springs on the shift rail may pop off
causing eye or face injury.
TRANSMISSION
29. Remove the snorkel tube and shaft assembly from 33. Lightly tap on the bearing from the opposite side to
the transmission case. remove it from the snorkel tube.
30. Remove the snap ring (Y) and shim (Z) from the 34. Remove the retaining ring to remove the remaining
snorkel shaft. washer, bearing and gear from the snorkel shaft.
31. Use an arbor press to remove the snorkel tube from

the snorkel shaft.
32. Remove the snap ring (A) and shim (B) retaining the
bearing in the snorkel tube.
TRANSMISSION
PLANETARY DIFFERENTIAL DISASSEMBLY 3. Remove the (6) planet gears and each side gear
assembly from the ring gear.
NOTE
If the gearcase is completely assembled, perform the
“Gearcase Disassembly and Inspection” procedure.
1. Use a scribe to mark the differential cover and ring

gear prior to disassembly.
4. Inspect the female side gear (A), male side gear (B),
planet gears (C) and ring gear (D). Replace
components or bushings as needed. Bushing
replacement can be performed on all necessary
differential components. If bushing replacement is
required, proceed to Planetary Differential Bushing
Replacement”.
2. Remove the (6) screws retaining the differential
cover and remove the cover.
PLANETARY DIFFERENTIAL BUSHING

REPLACEMENT
NOTE
If the differential is completely assembled, perform the
“Planetary Differential Disassembly” procedure.
Ring Gear Bushing Replacement

1. Press the old bushing out of the ring gear.
2. Thoroughly clean the bore of the ring gear and check
for any unwanted burs.
TRANSMISSION
3. Press the new bushing into the ring gear housing. 7. Press the new bushing into the planet gear until it is
flush on each end. Repeat this procedure for the
remaining planet gears.
Differential Cover Bushing Replacement

8. Press the old bushing out of the differential cover.
9. Thoroughly clean the bore of the differential cover
and check for any unwanted burs.
4. Install the bushing to the specified depth as shown.
10. Press the new bushing into the differential cover.
Planet Gear Bushing Replacement

5. Press the old bushing out of the planet gear.
6. Thoroughly clean the bore of the planet gear and
check for any unwanted burs.
TRANSMISSION
11. Install the bushing to the specified depth as shown. 14. Press the new bushing into the side gear until it
bottoms out.
PLANETARY DIFFERENTIAL ASSEMBLY

1. Thoroughly clean the differential components.
2. Assemble the side gears and place them onto the
ring gear along with the (6) planet gears.
Female Side Gear Bushing Replacement

12. Locate the bushing split. Using a small chisel or flat
blade screwdriver, peel back and remove the old
bushing from the side gear, being careful not to
damage the side gear.
3. Align and install the differential cover using the

previously made scribe marks.
4. Apply Loctite® 2760™ to cover screws.
13. Thoroughly clean the bore of the side gear and

check for any unwanted burs.
TRANSMISSION
5. Install screws hand tight. Place assembly in soft jaw TORQUE

vise and torque to specification.
Differential Cover Screws:
22 ft-lbs (30 Nm)
GEAR / SHAFT / BEARING INSPECTION
TRANSMISSION
SNORKEL GEAR BACKLASH PROCEDURE 5. Install the snorkel shaft into the gearcase. Using the
1. Reassemble the snorkel tube and snorkel shaft Snorkel Tool (PA-50231), tighten the snorkel tube
assembly by reversing the disassembly procedure until it is lightly seated in the transmission housing.
(see “Snorkel Shaft Removal / Disassembly”).
6. Inspect the pinion shaft assembly. Replace bearings

if needed. Inspect each gear for damage, chips or
abnormally worn teeth.
2. After the 13T gear and bearing are pressed onto the
snorkel shaft (flush to the shoulder), install the
washer and new retaining ring.
3. Press the gear back towards the retaining ring. Avoid
excessive force so the retaining ring is not damaged
or pre-stressed significantly.
NOTE
Failure to press the gear back against the washer and
retaining ring will lead to a gear backlash change after
vehicle is placed into service.
4. Apply a small amount of white lithium grease or Anti-

Seize on the threads of the snorkel tube.
NOTE
If pinion shaft was disassembled, the bearing cover
must be installed on the shaft before installing the 46T
gear.
7. Install the pinion shaft assembly. Be sure to properly

mesh the snorkel shaft bevel gear with the pinion
shaft bevel gear.
8. Apply Loctite® 242™ to the threads of the bearing
cover retaining screws.
TRANSMISSION
9. Using a 5 mm Allen wrench, install only the (3) 13. Slowly rotate the snorkel tube clockwise while
screws that secure the pinion shaft assembly as counting the number of notches passing through the
shown below. Leave the longer locking screw (A) out hole opening as you rotate the tube. Rotate the
at this point. snorkel tube to the 3rd notch from the ‘zero’
backlash position obtained in step 11.
NOTE 14. Check the pinion shaft gear backlash again by feel. If
DO NOT install the longer screw (A). Installing the the pinion shaft gear lash appears to be too tight,
longer screw will lock the snorkel tube and not allow for rotate the snorkel shaft clockwise to the next notch
backlash setting adjustment. (4th notch). 6
15. Once the backlash is set, apply Loctite® 242™ to the
10. Torque the bearing cover retaining screws to threads and install the locking screw to secure the
specification. snorkel tube.
TORQUE
Snorkel Bearing Cover Retaining Screws:
8 ft-lbs (11 Nm)
11. Rotate the snorkel tube counterclockwise using the

snorkel tool (PA-50231) until the snorkel gear and
pinion gear have ‘zero’ backlash.
NOTE
DO NOT overtighten the snorkel tube when backing it
out. At the 'zero' backlash position, you should still be
able to turn the snorkel shaft using your fingers, but it
will feel rough and may have some tight spots.
12. Look down into the transmission housing to see the

snorkel locking screw hole opening to reference your
starting point.
NOTE
If you have a hard time seeing into the hole, insert a
small Allen wrench, punch or screwdriver into the hole
to feel when the notch is aligned with the hole.
TRANSMISSION
16. Torque the locking screw to specification. 19. Apply Loctite® 242™ to two screws (T) and install
with retaining plates over shift fork. Torque to
specification.
TORQUE
Snorkel Locking Screw:
TORQUE
8 ft-lbs (11 Nm)
Shift Fork Screws:
10 ft-lbs (14 Nm)
Transmission Assembly
NOTE 20. Slide engagement dog (U) onto retaining pins of shift
fork.
The snorkel shaft and pinion shaft must be installed
prior to transmission assembly. The snorkel shaft
cannot be installed after assembling the transmission.
17. Clean both transmission case halves thoroughly.

Inspect case half mating surfaces for damage.
18. Install shift fork (S) and torsion spring into
transmission housing as an assembly. Load spring
as shown in image below
TRANSMISSION
21. Assemble the reverse shaft assembly and input shaft 22. Install the idler gear shaft assembly (A) and gear
assembly if previously disassembled (see cluster assembly (B) into the transmission housing,
illustrations). all at the same time.
23. Install the rear output shaft assembly (C). Rotate

output shaft assembly to align slots with engagement
dog. Ensure bearing is fully seated upon assembly.
TRANSMISSION
24. Assemble shift shaft rail if previously disassembled. 26. Inspect the shift drum for any damage or wear.
Inspect the splines of the shift drum.
27. Install the shift drum (E) into the transmission

NOTE housing. Lift up on the shift shaft rail (D) and move
Both shift forks need to be orientated the same way, so the rail assembly towards the shift drum to allow the
that the shift fork pins are both offset to the same side shift fork ends to be installed into the shift drum (E).
of the rail.
25. Install the shift shaft rail (D) and shift forks into the
transmission housing as an assembly. Be sure the
shift forks are engaged into the engagement dogs.
28. Apply a continuous bead of Crankcase 3 Bond

Sealant (PN 2871557) to the left hand transmission
mating surface.
NOTE
Shift fork pins should be offset towards the input shaft
as shown above.
TRANSMISSION
29. Install the transmission case cover and retaining 31. Thoroughly clean the shift shaft housing. Be sure
bolts. Torque bolts to specification. the transmission is in High gear prior to
reassembly.
32. Install the sector gear (16T) onto the shift drum shaft.
Install the shift shaft assembly and sector gear (11T)
into the bushing pocket on the left side. Align the
TORQUE timing marks on the gears as shown.
Transmission Case Bolts: 6
18 ft-lbs (24 Nm)
30. Install new seals into the transmission case halves.

• The snorkel shaft seal (F), should be pressed in until it
seats against the housing counter-bore.
• The input shaft seal (G), should be pressed in until it
seats flush with the housing.
• The rear output shaft seals (H) and pinion shaft seal
(J) can be installed using a standard bushing
installation tool. Seals should be installed just past the
case lead-in chamfer (.070" or 1.8 mm from outer face
of bore).
33. Install the spacer onto the shift drum shaft.
TRANSMISSION
34. Install the detent star onto the shift drum shaft. Be 40. Install the transmission drain plug and torque to
sure to install the detent star with the raised edge specification.
facing outward and skip-tooth aligned.
TORQUE
35. Install the detent pawl onto the shift shaft and
carefully install the compression spring. Transmission Fill / Drain Plug:
14 ft-lbs (19 Nm)
41. Install the bellcrank onto the shift shaft. Note the key
splined on the bellcrank and shift shaft. Install the nut
and torque to specification.
TORQUE
Bell Crank Nut:
15 ft-lbs (20 Nm)
42. Refer to “Transmission Installation” to complete the

repair.
36. Install a new O-ring on each shift shaft. Apply a small

amount of white lithium grease on the O-rings, shift
shafts and component contact surfaces prior to
installing the sector cover.
37. Clean the transmission and gear sector cover mating

surfaces thoroughly.
38. Apply Crankcase Sealant (3-Bond) (PN 2871557)
onto the cover and transmission case mating
surface.
39. Install the sector cover and align the transmission
case dowel with the alignment hole. Install and
torque the bolts to specification.
TORQUE
Sector Cover Bolts:
11 ft-lbs (15 Nm)
TRANSMISSION
TROUBLESHOOTING
TROUBLESHOOTING CHECKLIST
Check the following items when shifting difficulty is
encountered.
• Shift cable adjustment/condition
• PVT alignment (clutch center distance)
• Idle speed (throttle cable routing)
• Transmission lubricant type/quality
• Loose fasteners on sector gear cover
• Worn rod ends, clevis pins, or pivot arm bushings
• Shift selector rail travel
• Worn, broken or damaged internal transmission
components
NOTE
To determine if shifting difficulty or problem is caused
by an internal transmission problem, isolate the
transmission by disconnecting the shift cable end from
the transmission bellcrank. Manually select each gear
range at the transmission bellcrank, and test ride
vehicle. If it functions properly, the problem is outside
the transmission.
If transmission problem remains, disassemble 6

transmission and inspect all gear dogs for wear
(rounding) or damage. Inspect all bearings, circlips,
thrust washers and shafts for wear.
TRANSMISSION
TRANSMISSION
TRANSMISSION ASSEMBLY VIEW
TRANSMISSION
REF. DESCRIPTION REF. DESCRIPTION REF. DESCRIPTION

1. Plug, M18 34. Bearing, Ball 70. Gear, Low 67T
2. Magnetic Plug, M18 35. Bearing, Ball 71. Dog, Engagement
3. Plug, Cap Vent 5/16 36. Bearing, Needle 72. Gear, 53T
Screw, Hex Flange Head M8 x Bearing, Ball Gear, 46T
4. 37. 73.
1.25 x 30
Screw, Hex Flange Head M6 x 1 x Bearing, Ball Gear, 13T Snorkel
5. 38. 74.
20
6. Screw, Hex Flange Head M8 x 50 39. Spring, Compression 75. Shaft, Shift
Screw, Socket Head M6 x 1.0 x Spring, Compression Weldment, Rear Mount Bracket
7. 40. 76.
40
8. Screw, Socket Head 41. Spring, Torsion Return 77. Subassembly, Differential
9. Screw, Torx M6 x 1.0 x 18 42. Spring, Compression 78. Retainer, Fork
10. Nut, Lock Hex Flange M8 x 1.25 43. Spring, Compression 79. Bracket, Rear Mount
11. Washer, Cup 44. Spring, Wave 80. Cover, Bearing, Center Drive
12. Plate, Park 12–face 45. Tube, Snorkel 81. Spacer
13. Washer 46. Cover, Sector Gears 82. Chain, Silent .25P x .40W x 58L
14. Washer 47. Subassembly, LH Case 83. Diff Solenoid
15. Washer 48. Subassembly, RH Case 84. Switch, Rotary 2–pin
16. Pin, Dowel 6 x 20 49. Drum, Shift 85. O-ring
6
17. Pin, Spring, Slotted 6 x 12 50. Gear, Sector 16T 86. O-ring
18. Ring, Retaining 51. Gear, Sector 31T 87. O-ring
19. Ring, Retaining 56. Shaft, Reverse 25T 88. Seal, Triple Lip 25 x 80 x 10
20. Ring, Retaining 57. Shaft, Front Output 89. Seal, Dual Lip 25 x 47
21. Ring, Retaining 58. Shaft, Input 90. Seal, Triple Lip 40 x 70 x 7
22. Ring, Retaining 59. Subassembly, Pinion 92. Sensor, Speed
23. Ring, Retaining 60. Bellcrank 95. Bracket, Wire Harness
24. Ring, Retaining 61. Collar, Shift 96. Plug, Expansion 1 1/4
25. Ring, Retaining 62. Rail, Shift Shaft 97. Subassembly, 39T Side Gear
26. Ring, Retaining 63. Tube, Vent 98. Bearing, Plain 40 x 44 x 15
Washer, Thrust Fork, Pivot Shift Subassembly, 39T Side Gear

27. 64. 99.
Disconnect
28. Washer, Thrust 65. Dog, Engagement 100. Subassembly, Diff Cover
29. Shim, 1.180 OD x .995 ID 66. Shift Dog, Park 101. Subassembly, Planet Gear
30. Shim 2.040 OD x 1.63 ID 67. Gear, 48T 102. Subassembly, Gear 53T
31. Bearing, Needle 68. Subassembly, Shift Fork 104. Screw, Cap M8 - 1.25 x 25
32. Bearing, Ball 69. Sprocket, 48T 105. Bracket, Wire Harness
33. Bearing, Ball
TRANSMISSION
NOTES
FINAL DRIVE
CHAPTER 7
FINAL DRIVE
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
FINAL DRIVE TORQUE TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
FRONT HUB / BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
HUB REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
HUBSTRUT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.4
HUB INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.5
FRONT HUB/WHEEL EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.7
FRONT DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
FRONT DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8
FRONT DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.9
FRONT GEARCASE REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10
GEARCASE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.10
GEARCASE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.11
FRONT GEARCASE / CENTRALIZED HILLIARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.12
FRONT DRVIE (NON-ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.12
FRONT GEARCASE ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.12
ALL WHEEL DRIVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.13 7
AWD DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.14
GEARCASE DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.15
GEARCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.18
FRONT GEARCASE (ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.21
EXPLODED VIEW, FRONT GEARCASE (4WDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.21
OPERATION, FRONT GEARCASE (4WDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.23
DISASSEMBLY / INSPECTION, FRONT GEARCASE (ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.24
REASSEMBLY, FRONT GEARCASE (ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.27
TROUBLESHOOTING, FRONT GEARCASE (ADC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.30
REAR BEARING CARRIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.33
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.33
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.34
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.35
REAR DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.37
REAR DRIVE SHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.37
REAR DRIVE SHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.37
DRIVE SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.38
DRIVE SHAFT / CV JOINT HANDLING TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.38
OUTER CV JOINT / BOOT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.38
INNER PLUNGING JOINT / BOOT REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.41
DRIVE SHAFT ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.43
FINAL DRIVE
PROPSHAFT U-JOINT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.44

REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.44
FRONT PROP SHAFT COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.44
REMOVAL / INSTALLATION (CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.44
SUPPORT BEARING REPLACEMENT (CREW). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.45
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.46
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.47
FINAL DRIVE
GENERAL INFORMATION
SPECIAL TOOLS
PART TOOL DESCRIPTION
NUMBER
2872608 Roll Pin Removal Tool
PU-48951 CV Boot Clamp Tool
or 8700226

FINAL DRIVE TORQUE TABLE

ITEM SPECIFICATION
Brake Caliper Mount Bolt 46 ft-lbs (62 Nm)
Front Hub Castle Nut 90 ft-lbs (122 Nm)
Rear Hub Castle Nut 110 ft-lbs (150 Nm)

Prop Shaft Support
36 ft-lbs (49 Nm)
Bearing Fasteners
Prop Shaft Bearing Set 35 in-lbs (4 Nm)
Screws
Wheels)
36 ft-lbs (49 Nm)
7
Wheel Lug Nuts 30 ft-lbs + 90º (41 Nm +
(Aluminum Wheels) 90º)
FINAL DRIVE
FRONT HUB / BEARING

HUB REMOVAL / INSPECTION 6. Rotate each bearing r by hand and check for
1. Elevate and safely support front end of the machine smooth rotation. Visually inspect bearing for
under the footrest / frame area. moisture, dirt, or corrosion. Replace bearing if
moisture, dirt, corrosion, or roughness is evident.
CAUTION
procedure. Wear eye protection when removing
bearings and seals.
2. Check bearings for side play by grasping the tire /

wheel firmly and checking for movement. Grasp the
top and bottom of the tire. The tire should rotate
smoothly without binding or rough spots.
HUBSTRUT BEARING REPLACEMENT

Bearing Removal
1. Remove outer snap ring q.
3. Remove wheel nuts, washers, and wheel.

4. Remove the two brake caliper mounting bolts.
CAUTION
Do not hang the caliper q by the brake line. Use wire to
hang the caliper to prevent possible damage to the
brake line.
2. From the back side, tap on the outer bearing race

with a drift punch in the reliefs as shown in Step 3.
5. Remove hub cap, cotter pin e, front spindle nut w,

and washer.
FINAL DRIVE
3. Drive bearing out evenly by tapping on outer race 7. Wipe the housing clean of any excess compound
only. Once bearing is at bottom of casting, support and install the retaining ring.
casting on outer edges so bearing can be removed.
HUB INSTALLATION
1. Inspect the hubstrut bearing surface for wear or
damage.
2. Apply anti-seize to drive axle spindle.
3. Install spindle through the backside of the hubstrut.
Install the hub onto the spindle.
NOTE
While rotating bearings by hand, inspect for rough
spots, discoloration, or corrosion. The bearings should
turn smoothly and quietly, with no detectable up and
down movement and minimal movement sideways
between inner and outer race. 4. Install cone washer with domed side out.
4. Inspect bearing hubstrut housing for scratches, wear

or damage. Replace hubstrut housing if damaged. 7
Bearing Installation
5. Thoroughly clean the hubstrut housing and the outer
race on the new bearing. Be sure that all oil residue
has been removed from each surface.
6. Apply Loctite RC™ 680 to the outer circumference
of the new bearing race w and carefully install the
new bearing into the strut housing.
5. Install flat washer and spindle nut and tighten to

specification.
TORQUE
Front Hub Nut Torque:
90 ft-lbs (122 Nm)
6. Install a new cotter pin. Tighten nut slightly if

necessary to align cotter pin holes.
7. Rotate wheel and check for smooth operation. Bend
both ends of cotter pin around end of spindle in
NOTE different directions.
Use care to not allow any of the Loctite compound to 8. Install hub cap.
get in the bearing.
FINAL DRIVE
9. Rotate hub. It should rotate smoothly without binding

or rough spots or side play.
10. Install brake caliper using new bolts q. Tighten bolts
to specified torque.
TORQUE
Brake Caliper Bolt Torque:
46 ft-lbs (62 Nm)
CAUTION
New brake disc bolts have a pre-applied locking agent
which is destroyed upon removal. Always use new
brake disc mounting bolts upon assembly if removed.
11. Install wheel, washers, wheel nuts, and tighten

evenly in a cross pattern to specified torque.
Refer to “Torque Specifications”.
FINAL DRIVE
FRONT HUB/WHEEL EXPLODED VIEW

7
q Cotter Pin
w Castle Nut 90 ft-lbs (122 Nm)
e Washer
r Wheel Nut Steel Wheel Nuts:

36 ft-lbs (49 Nm)
30 ft-lbs + 90º (41 Nm + 90º)
t Washer
y Tire
u Rim
i Front Hub
o Stud
a Brake Disc
s Bolt
FINAL DRIVE
FRONT DRIVE SHAFT

FRONT DRIVE SHAFT REMOVAL 6. Remove the front wheel hub.
1. Elevate front of vehicle and safely support machine
under the frame area.
CAUTION
bearings and seals.
2. Check bearings for side play by grasping tire / wheel

firmly and checking for movement. It should rotate
smoothly without binding or rough spots.
7. Remove cotter pin w and castle nut e from A-arm

ball joint.
3. Remove the four wheel nuts and remove the front

wheel.
4. Remove the brake caliper mounting bolts q.
8. Remove lower A-arm from ball joint using a tie rod

fork.
CAUTION
Do not hang the caliper by the brake line. Use wire to
hang the caliper to prevent possible damage to the
brake line.
5. Remove and discard the cotter pin, then remove the

front hub castle nut.
FINAL DRIVE
9. Pull strut assembly out while pivoting front drive shaft 3. Install the lower A-arm onto the lower ball joint,
downward until it clears strut assembly. torque nut q to specification and install new cotter
pin w.
10. With short sharp jerks, remove drive shaft from front
gearcase. 4. Install hub and tighten spindle nut to specification.
Install a new cotter pin
5. Install the brake caliper. Torque fasteners to
specification.
TORQUE
Ball Joint Nut Torque:
30 ft-lbs (41 Nm)
Front Hub Nut Torque:

90 ft-lbs (122 Nm) 7
Brake Caliper Bolt Torque:
46 ft-lbs (62 Nm)
FRONT DRIVE SHAFT INSTALLATION

1. Install new spring ring on drive shaft. Apply an anti-
seize compound to splines. Align splines of drive
shaft with front gearcase and install by lightly tapping
on drive shaft with rubber faced hammer.
2. Install drive shaft into strut housing.
FINAL DRIVE
FRONT GEARCASE REMOVAL AND INSTALLATION

GEARCASE INSTALLATION 5. Connect the AWD wire harness (Item 4).
1. Install the gearcase back into the vehicle through the
left-hand wheel well area, between the upper and
lower A-arms.
6. Refer to “FRONT DRIVE SHAFT - Drive Shaft

Installation” and install both front drive shafts into the
gearcase.
2. Install the propshaft onto the front gearcase input 7. Add the proper lubricant to the front gearcase. Refer
shaft. Use a NEW spring pin in the front propshaft. to Chapter 2 for fluid fill and change information.
3. Install the (4) bolts that secure the front gearcase to
the frame and torque to specification. Polaris Demand Drive
(PN 2877922)
4. Install the vent line (Item 3) and attach wire harness Front Housing Capacity
(Item 2) to the retaining dart. 6.7–7.6 fl. oz. (200–225 ml)
TORQUE
Front Gearcase Mounting Bolts:
33 ft-lbs (56 Nm)
FINAL DRIVE
GEARCASE REMOVAL 7. Remove the gearcase from the front LH wheel well
1. Stop engine and place gear selector in Park. area and slide it between the upper and lower A-arm.
2. Refer to “FRONT DRIVE SHAFT - Drive Shaft

Removal” and remove both front drive shafts from
the front gearcase.
3. Remove the propshaft from the front gearcase. (see
“PROPSHAFT SERVICE”).
4. Disconnect the wire harness above the front
gearcase (Item 1) and remove the harness (Item 3)
from the retaining dart.
5. Remove the vent line (Item 4) from the front

gearcase.
6. Remove the (4) bolts (Item 2) securing the front
7
gearcase to frame.
FINAL DRIVE
FRONT GEARCASE / CENTRALIZED HILLIARD

FRONT DRVIE (NON-ADC)
FRONT GEARCASE ASSEMBLY VIEW
REF# DESCRIPTION QTY REF# DESCRIPTION QTY

1 O-Ring 1 19 Hub Sub-Assembly (Female) 1
2 O-Ring 1 20 Hub Sub-Assembly (Male) 1
3 Dowel Pin 1 21 Rollers 20
4 Vent Hose Fitting 1 22 Torsion Spring 1
5 Ball Bearing 2 23 Spring, Wireform 2
6 Ball Bearing (Double Row) 1 24 H-Clip Spring 20
7 Bushing 1 26 Nylon Spacer 2
8 Bushing 1 27 Torsion Spring Retainer 1
9 Oil Seal 2 28 Backlash Spacer 1
10 Oil Seal 1 29 Ring Gear Spacer 1
11 Retaining Ring, Internal 1 30 Pinion Gear 1
12 Cover Screws, M6 (T30 Torx) 7 31 Armature Plate 1
13 Cover Plate Assembly 1 32 AWD Coil 1
14 Gearcase Housing 1 35 Fill Plug 1
15 Clutch Housing (Ring Gear) 1 36 Drain Plug, Magnetic 1
16 Roll Cage 1 38 Retaining Ring, External 1
18 Hub / Race Assembly 2
FINAL DRIVE
ALL WHEEL DRIVE OPERATION

The AWD switch may be turned on or off while the
vehicle is moving, however, AWD will not enable until the
engine RPM drops below 3100. Once the AWD is
enabled, it remains enabled until the switch is turned off.
Engage the AWD switch before getting into conditions
where the front wheel drive may be needed. If the rear
wheels are spinning, release the throttle before switching
to AWD.
CAUTION
Switching to AWD while the rear wheels are spinning
may cause severe drive shaft and gearcase damage.
Always switch to AWD while the rear wheels have
traction or are at rest.
With the AWD switch off, the vehicle drives through the AWD Disengagement: Once the rear wheels regain
rear wheels only (2 wheel drive). When the AWD is traction, the front wheels will return to the “over-running”
enabled, the front drive acts as an on-demand AWD condition. The vehicle is now back to rear wheel drive
system. This means, the front drive will engage once the until the next loss of rear wheel traction occurs.
rear wheels have lost traction, and will remain engaged Torsion Spring Operation: The torsion spring acts as a
until the torque requirement goes away (i.e. rear wheels return mechanism to help disengage the coupling of the
regain traction). output hubs and ring gear by creating an “over-running”
condition for the rollers upon disengagement.
CAUTION
If the rear wheels are spinning, release the throttle
before turning the AWD switch on.
If AWD is engaged while the wheels are spinning, 7

severe drive shaft and front gearcase damage could
result.
AWD Engagement: When the AWD switch is activated,

the AWD coil is powered by a 12 Vdc input which creates
a magnetic field. This magnetic field attracts an armature
plate that is keyed to the roll cage. When the ring gear
and roll cage are spinning (vehicle is moving), the
energized coil and armature plate will apply drag to the
roll cage that indexes the rollers inside the ring gear to an
engagement position. While in the engagement position,
the front drive will be in an “over-running” condition (not
engaged), until the rear wheels lose traction. Once the
rear wheels begin to lose traction, the front drive will
engage by coupling the output hubs to the ring gear via
the rollers. The front drive will remain engaged until the
torque requirement goes away (i. e. rear wheels regain
traction).
FINAL DRIVE
AWD DIAGNOSIS 5. Check to make sure the coil is seated in the U-

shaped insert that is pressed into the gearcase
Symptom: AWD Will Not Engage
cover. The top of the coil should be seated below the
1. Check the gearcase coil resistance. To test the coil U-shaped insert. The U-shaped insert controls the
resistance, measure between the Grey and Brown/ pole gap. If the top of the coil is above the surface of
White wires. The measurement should be within the U-shaped insert it raises the armature plate,
specification. thereby increasing pole gap. If the pole gap
increases the coil will not be strong enough to
engage the AWD system. If this is found, replace the
cover plate assembly.
Front Gearcase Coil Resistance:

21.6 - 26.4 Ω
2. Turn the ignition and AWD switches on and place

gear selector in High or Low gear. Check for
minimum battery voltage at the Gray and Brown/
White chassis wires that power the coil. A minimum 6. Inspect the rollers for nicks and scratches. The
of 11 Vdc should be present. rollers must slide up, down, in and out freely within
the roll cage sliding surfaces and H-springs.
3. If electrical tests are within specification, remove
gearcase (see “Gearcase Removal”) and inspect 7. Inspect the roll cage assembly for cracks or
components. excessive wear. If damaged, replace the roll cage
assembly.
4. Inspect the armature plate for a consistent wear
pattern. There should be two distinct wear bands
(one band inside the other). If only one band of wear
is present (or if there is wear between the two
bands), inspect the coil area as indicated in Step 5. A
wear band with an interrupted wear mark may
indicate a warped plate, which may cause
intermittent operation. See the following illustrations:
FINAL DRIVE
GEARCASE DISASSEMBLY / INSPECTION 3. Remove the LH output hub assembly from the clutch
housing or outer cover plate assembly.
1. Drain and properly dispose of gearcase fluid.
Remove any metal particles from the drain plug
magnet.
2. Remove the (7) cover screws and remove the cover
plate assembly.
NOTE
Nylon spacer is non-serviceable and should not be
removed.
FINAL DRIVE
4. Remove and inspect the armature plate. Refer to 6. Remove the clutch housing / ring gear and roll cage
“AWD Diagnosis” for detailed inspection process. assembly from the gearcase housing.
5. Remove the torsion spring retainer and torsion 7. Remove the RH output hub assembly from the
spring from the top of the ring gear. gearcase housing.
FINAL DRIVE
8. Remove pinion seal, internal retaining ring and 10. Inspect the AWD coil located in the outer cover plate
pinion gear assembly from the gearcase housing. assembly. Refer to “AWD Diagnosis” for detailed
Inspect and clean the gearcase housing and replace inspection process. Replace the cover plate seal and
all oil seals and O-rings. O-ring.
11. Remove the roll cage assembly and rollers from the
clutch housing. Use a shop towel to cover the
9. Inspect the pinion gear for chipped, broken or housing in order to retain all the rollers.
missing teeth. Inspect the pinion bearing for signs of
wear and the pinion shaft seal surface for pitting. NOTE
Rollers are spring loaded. Take care not to allow them
to fall out or lose them upon removal of the roll cage.
12. Thoroughly clean all parts and inspect the rollers (A) 7
for nicks and scratches. The rollers must slide up
and down and in and out freely within the roll cage
(B) sliding surfaces and H-springs.
NOTE
Refer to the “Electronic Parts Catalog” for individual
part availability. Most parts are to be replaced as an
assembly or as a complete kit.
FINAL DRIVE
13. Inspect clutch housing ring gear (C) for a consistent GEARCASE ASSEMBLY
wear pattern. Inspect the ring gear for chipped,
1. As mentioned during gearcase disassembly section,
broken, or missing teeth.
replace all O-rings, seals and worn components.
14. Inspect the roll cage assembly (B) sliding surfaces
2. Install pinion shaft assembly and install internal snap
and H-springs. The sliding surfaces must be clean
ring.
and free of nicks, burrs or scratches. If damaged,
replace the roll cage assembly. NOTE
If bearing replacement was required, press new bearing
onto the pinion shaft and install a new external snap
ring.
3. Install a new pinion shaft seal into the pinion gear

housing. Using a universal seal installer, press the
new seal into the housing until the seal is just below
the housing chamfer.
15. Inspect both output hub assemblies. Inspect the

bearings and replace if needed.
4. Install the RH output hub into the gearcase housing.
16. Clean and inspect all remaining front gearcase

components. Check each for excessive wear or
damage.
FINAL DRIVE
5. Carefully install the rollers into the roll cage 7. Align the spring retainer dowel pin with the ring gear
assembly while installing the assembly into the dowel pin and install the retainer on top of the torsion
clutch housing. spring.
NOTE
Install the roll cage so that the ring gear grooves line up
with the roll cage slots (see below).
8. Check the action of the torsion spring by rotating in

both directions to ensure the spring and retainer are
installed properly.
6. Install the torsion spring by wrapping each leg of the

spring around the dowel pin on the ring gear.
FINAL DRIVE
9. Be sure the armature plate tabs are fully engaged 12. Carefully install the LH output hub assembly into the
into the roll cage assembly and are resting on the cover plate. Take care not to damage the new cover
cut-grooves of the ring gear. plate seal while installing the output hub.
NOTE 13. Install the output cover assembly onto the gearcase
Verify armature plate tabs are in the slots on the roll housing. Install the (7) cover plate screws and torque
to specification.
cage and are resting in the ring gear grooves.
10. Carefully install the ring gear and roll cage assembly
into the gearcase housing.
TORQUE
Front Gearcase Cover Plate Screws:
11 ft-lbs (15 Nm)
11. Install a new O-ring on the cover plate assembly.
NOTE
Be sure the square O-ring is placed flat on the cover
surface. If the O-ring is twisted fluid leakage may occur.
FINAL DRIVE
FRONT GEARCASE (ADC)
EXPLODED VIEW, FRONT GEARCASE (4WDC)
FINAL DRIVE
REF. PART DESCRIPTION NOTES

1 ASM., GEARCASE, RH, ADC, 4WDC [INCL.
ALL]
2 ASM., COVER, OUTPUT
3 ASM., OUTPUT HUB
4 KIT, FASTENERS Torque: 8 ft-lbs (11 Nm)
5 KIT, SEAL REPAIR
6 PLATE, ARMATURE
7 PLATE, ARMATURE, BD
8 BEARING
9 KIT, ROLLER [SET OF 20]
10 ASM., ROLL CAGE [INCL. CAGE, 20 CLIPS]
11 ASM., GEARCASE
12 ASM., PLUG, DRAIN Torque: 11 ft-lbs (15 Nm)
13 PLUG, OIL FILL Torque: 8-10 ft-lbs (11-14 Nm)
14 RING, RETAINING, INTERNAL
15 KIT, SPRING
16 RING, RETAINING, EXTERNAL
17 ASM., GEAR HOUSING AND PINION GEAR
FINAL DRIVE
OPERATION, FRONT GEARCASE (4WDC)

The active descent control front gearcase is designed to allow the vehicle to operate in 2x4, 4x4, or utilize the vehicles
EBS to allow 4x4 ADC (active descent control) in the forward and reverse direction.
IMPORTANT
All-wheel drive ADC MUST be selected on the all-wheel drive / ADC switch to activate the ADC system.
When the vehicle is in 2x4, all coils within the gearcase are off. This allows the pinion and ring gear to spin without
engaging the front gearcase output hubs.
When the vehicle is in 4x4, the 4 wheel drive coil is turned on but the ADC coil remains off. Turning on the 4 wheel
drive coil applies drag to the outer armature plate. The outer armature plate is connected to the roller cage, which
engages the rollers in the cage with the forward / reverse ramp in the bi-directional clutch. In the event that the vehicle
wheels roll down a hill faster than it is being driven, ADC will not slow the vehicle.
When the vehicle is in 4x4 ADC, the AWD coil is turned on and the ADC coil remains off until necessary. When
descending a hill, the EBS slows the driveline and rear wheels. The ADC coil detects the speed difference and locks
the front wheels to the driveline. The front wheels can now assist in controlling the descent. Turning on the ADC Coil
applies drag to 2 inner armature plates. One armature plate is connected to an output hub and the other is connected
to the roller cage. The frictional drag between the two armature plates causes the output hub to rotate the roller cage,
which engages the rollers in the cage with the forward / reverse ramp in the bi-directional clutch. Because the hubs
rotate faster than the driveline in an engine breaking situation this combination of events slows the vehicle when the
clutch engine brake system is active allowing true four wheel engine braking in forward / reverse gears.
During engine braking the front drive can also speed differentiate across the axle when turning. Also, if the outer wheel
slips or loses traction the inner wheel will then begin to slow the vehicle as well.
FINAL DRIVE
DISASSEMBLY / INSPECTION, FRONT GEAR-

CASE (ADC)
1. Drain and properly dispose of used oil. Remove any
metal particles from the drain plug magnet q.
4. Remove the output hub assembly e.
2. Remove bolts w retaining the outer cover plate

assembly.
5. Inspect the bearing and contact surfaces of the output

hub for signs of wear or damage. Replace component
if found to be worn or damaged.
3. Remove the outer cover plate assembly.
NOTE
Press on the output hub assembly e while lifting up on
the outer cover plate(4) to prevent removing more than
the cover plate.
6. Remove and inspect the armature plates t. Refer to

“AWD Diagnosis” for detailed inspection process.
FINAL DRIVE
7. Remove the torsion spring retainer y. 10. Remove the LH output hub s.
7
8. Remove the torsion spring u from the top of the ring 11. Inspect the bearing and contact surfaces of the output
gear i. hub for signs of wear or damage. Replace component
if found to be worn or damaged.
9. Remove the roll cage assembly o, rollers a, and

ring gear i. Inspect for wear. 12. Thoroughly clean all parts. Inspect the bearing
surfaces of the output hub. Inspect the rollers a for
nicks, scratches and flat spots. Inspect the roll cage
o for damage or cracks. The rollers must slide up
and down freely within the roller cage surfaces.
FINAL DRIVE
13. Inspect the ring gear i for inconsistent wear patterns

or damage. The surfaces should be free of nicks or 16. Drill a hole in the input shaft seal d and remove the
burrs. seal using a pry bar or seal puller.
14. Inspect roll cage (B) sliding surface. This surface
must be clean and free of nicks, burrs or scratches.
Inspect the H-springs, but do not remove them
from the roll cage.
17. Remove the snap ring retaining the input shaft

assembly.
15. Inspect the armature plate for a consistent wear

pattern. Uneven wear of the armature plate indicates
a warped plate, which may cause intermittent
operation.
NOTE
See “FRONT GEARCASE DIAGNOSIS” later in this
chapter for more details.
18. Remove the input shaft assembly. Inspect the pinion

gear g for chipped, broken, or missing teeth. Inspect
the input shaft bearing h for signs of wear. Replace
the input shaft cover O-ring prior to reassembly.
FINAL DRIVE
REASSEMBLY, FRONT GEARCASE (ADC)

1. Clean the gearcase housing of debris.
2. Replace all O-rings, seals, and worn components.
3. Inspect bearings on output and pinion shafts. To
replace, press new bearing onto shaft.
NOTE
down movement and minimal movement side to side.
19. Inspect the input shaft bushing j for wear.
4. Install input shaft, bearing, and snap ring.
7
20. Thoroughly clean the gearcase components before
beginning reassembly. 5. Press the pinion shaft seal into the gearcase, until the
seal is flush.
6. Install the LH output hub s into the gearcase

housing. The output hub should spin freely.
FINAL DRIVE
7. Install the torsion spring by wrapping each leg of the 11. Check the action of the torsion spring by rotating in
spring around the dowel pin on the ring gear. both directions to ensure the spring and retainer are
8. Install the rollers and roll cage into the ring gear. installed properly.
Insert the rollers as the roll cage is installed. 12. Install the armature plates t. Be sure the armature
plate tabs are fully engaged into the roll cage
assembly.
9. Install the pins a, roll cage o, and ring gear

assembly i into the gearcase housing.
NOTE
Verify armature plate tabs are in the slots on the roll
cage and are resting in the ring gear grooves.
13. Install the RH output hub e into the gearcase

housing. The output hub should spin freely.
10. Align the spring retainer dowel pin with the ring gear
dowel pin and install the retainer y on top of the
torsion spring.
FINAL DRIVE
TORQUE
Fill Plug:
8-10 ft-lbs (11-14 Nm)
Drain Plug:
11 ft-lbs (15 Nm)
14. Install the cover plate assembly with a new o-ring

onto the gearcase.
NOTE
Verify the square O-ring is placed flat on the cover
surface. If the O-ring is twisted, fluid leaks may occur.
15. Torque the cover plate bolts w to specification.
TORQUE
AWD Cover Screws:
8 ft-lbs (11 Nm)
16. Fill the gearcase with fluid.
FLUID CAPACITY
Demand Drive
Hub Fluid
8.97 oz. (265 ml)
17. Install the drain plug. Torque to specification.
FINAL DRIVE
TROUBLESHOOTING, FRONT GEARCASE

(ADC)
Customer Complaint: ADC not functioning
Verification of complaint: Drive vehicle with ADC switched on and off down a grade if possible to determine if ADC
(Auto-lock is working correctly). May need to be in low range to tell in high traction areas. Make sure switch on handle
bar is on ADC mode. Make sure ADC light is lit on gage pod. Vehicle must be in hi, low, or reverse. Also, vehicle
throttle lever must be off. If complaint is warranted, move onto component check list. If no, move onto other vehicle
components (suspension, driveline, engine, etc.) Vehicle may also be tested in air. All 4 wheels need to be off ground,
put into ADC mode and roll back wheels if possible. Rotate cover side front wheel forward and back, should feel roll
cage in front drive index and lock the front wheel to the drive line. This can only be done on the cover side wheel. It is
also best to make sure 4x4 is not engaged any more. This way is possible to test but best way is to ride vehicle down
steep hill as stated above.
POTENTIAL DIAGNOSIS PROBLEM REPAIR REPAIR

PROBLEM PROCEDURE DIAGNOSIS PROCEDURE VERIFICATION
Check to see if ADC light No ADC light on gage Problem might not be front N/A
is lit on gage pod. pod. differential related. Check
electrical system in
vehicle.
Check wires to see if there Cut wire. Replace output cover (Unit Drive vehicle with ADC
are any visible cuts or will need to be removed mode on to determine if
Unplugged / damaged nicks. from vehicle to do repair.) problem has been fixed. If
wire connector. not, continue onto
additional problems listed.
Check to see if front Unplugged Plug wire harness into Drive vehicle with ADC
differential is plugged into front drive connector. mode on to determine if
wire harness. problem has been fixed. If
not, continue onto
Differential installed in vehicle

No power from vehicle to Unhook wire connector to No power to front Problem might not be front N/A
front differential (blown front differential. Using differential wire harness. differential related. Check
fuse) multimeter determine if electrical system in
vehicle wire connector is vehicle.
getting power to the front
drive on two outer most
pins.
ADC Coil Short Check resistance of coil Coil to be +/- 4 ohms to Replace output cover (Unit Drive vehicle with ADC
nominal will need to be removed mode on to determine if
from vehicle to do repair.) problem has been fixed. If
not, continue onto
Check continuity to both Continuity should be Replace output cover (Unit Drive vehicle with ADC
leads present between leads. will need to be removed mode on to determine if
not, continue onto
Check continuity to case No continuity between Replace output cover (Unit Drive vehicle with ADC
Check continuity to case either lead and the case. will need to be removed mode on to determine if
not, continue onto
4x4 Not turning off Lift Vehicle off ground. Power to 4x4 is not Problem might not be front N/A
Rotate cover side wheel in turning off when ADC is differential related. Check
both the forward and turning on. electrical system in
reverse direction. If it locks vehicle.
to the drive train in only
one direction, ADC is not
indexing cage in both
directions
FINAL DRIVE
POTENTIAL DIAGNOSIS PROBLEM REPAIR REPAIR

PROBLEM PROCEDURE DIAGNOSIS PROCEDURE VERIFICATION
Hub Plate Hub Plate will be attached Plate should be flat. Plate Replace hub plate or hub Drive vehicle with ADC
to output hub. Initially look should have even wear assembly with hub plate. mode on to determine if
at plate and see if any on both sides and no May need to replace Hub problem has been fixed. If
excessive wear is present. significant gauging plate and Armature plate not, continue onto
Look and see if plate is should be present. at the same time. additional problems listed.
bent or warped. Look to
see if any debris is on
plate or debris is causing
uneven wear. To do further
evaluation plate would
need to be removed from
hub, by removing bearing.
Plate then can be placed
on a flat surface to
determine if plate is flat.
ADC Armature Plate Place Plate on flat surfacePlate should not have Replace Armature plate. Drive vehicle with ADC
with tangs up to check for significant rock when May need to replace both mode on to determine if
flatness. Also look for pushing on one side of Armature plate and hub problem has been fixed. If
even wear on surface the plate. Plate should plate at the same time. not, continue onto
Differential removed from vehicle
towards Hub plate also have even consistent additional problems listed.
wear on the surface.
Roll Cage Check to see if cage is Roll cage should have no Replace roll cage Drive vehicle with ADC
broken or cracked. Look to cracks or breaks. Springs assembly (cage and mode on to determine if
see if any springs are should have no cracks spring). Always replace problem has been fixed. If
broken or stuck in place. and fully intact. Clutch both. (do not take springs not, continue onto
Look to see if cage can should be able to off old cage and put onto additional problems listed.
index properly in both advance down the new cage).
directions engagement ramp
smoothly.
Torsion Spring Make sure Spring is Plastic retainer should If torsion spring is not Drive vehicle with ADC
installed properly. Make index with some force installed correctly, install mode on to determine if
sure Spring is able to from spring. Retainer correctly and retest. If problem has been fixed. If
index properly in both should also index far other issue with retainer or not, continue onto
directions enough to allow clutch to
engage.
spring, replace one or both
and retest.
additional problems listed. 7
Cover Side Hub Check to see if Hub plate If Hub plate can not slide Replace with new hub Drive vehicle with ADC
can slide on hub spline. it may not engage coil assembly and Hub Plate. mode on to determine if
correctly. problem has been fixed. If
not, continue onto
ADC Coil/Coil Pocket Check Pole Faces for Pole faces should be Clean off pole faces if no Drive vehicle with ADC
(Output Cover) debris smooth and even wear significant wear is noticed. mode on to determine if
should be present. If pole faces are severely problem has been fixed. If
worn and damaged, not, continue onto
replace output cover. additional problems listed.
Check for Coil raised Coil should be well below Replace output cover. Drive vehicle with ADC
above pole faces the pole faces. If coil is mode on to determine if
outside pole faces it problem has been fixed. If
would cause the plates not, continue onto
not to touch the pole additional problems listed.
faces.
Check Wear on Pole faces Pole faces should be Clean off pole faces if no Drive vehicle with ADC
smooth and even wear significant wear is noticed. mode on to determine if
should be present. If pole faces are severely problem has been fixed. If
worn and damaged, not, continue onto
replace output cover. additional problems listed.
FINAL DRIVE
Symptom: AWD Will Not Engage 4. Check to make sure the coil t is seated in the U-
shaped y insert that is pressed into the gearcase
1. Check the gearcase coil resistance. To test the
cover u. The top of the coil should be seated below
gearcase coil resistance, use the coil harness (Grey
the U-shaped insert. The U-shaped insert controls the
& Brown/White).
pole gap. If the top of the coil is above the surface of
NOTE the U-shaped insert it raises the armature plate,
thereby increasing pole gap. If the pole gap increases
To test the gearcase coil resistance, use the coil the coil will not be strong enough to engage the AWD
harness. The gearcase coil should measure between system. If this is found, replace the cover plate
22.8 ohms and 25.2 ohms. assembly.
ADC Front Gearcase Coil Resistance

B-C (4X4): 23 Ω ±4Ω 5. Inspect the rollers for nicks, scratches, and flat spots.
A–D (4X4 ADC): 12.49 Ω ±4Ω Also inspect the roll cage o for cracks and ensure
the rollers a are able to slide up and down and in and
out freely within the roll cage sliding surfaces.
2. Check the minimum battery voltage at the Grey &
Brown/White wires that feed the hub coil wires.
AWD Coil Applied Battery Voltage:
11.80-12.0 Vdc
3. Inspect the armature plate e for a consistent wear

pattern. There should be two distinct wear bands r
(one band inside the other). If only one band of wear
is present (or if there is wear between the two bands,
inspect the coil area as indicated in Step 4. A band
with an interrupted wear mark may indicate a warped
plate, which may cause intermittent operation.
FINAL DRIVE
REAR BEARING CARRIER

INSPECTION 4. Remove the two brake caliper mounting bolts r and
1. Support the machine securely with rear wheels remove the caliper from the bearing carrier.
elevated.
CAUTION
bearings and seals.
2. Check the bearings for side play. Grasp the top and
bottom of the wheel or wheel hub and check for
movement.
3. If movement is detected, inspect wheel hub, castle
nut torque and bearing condition. The tire should
rotate smoothly without binding or rough spots.
Correct as necessary.
CAUTION
REMOVAL Do not hang the caliper by the brake line. Use
1. Elevate the rear end of the vehicle and safely mechanics wire to hang the caliper to prevent possible
support the vehicle under the main frame area. damage to the brake line.
2. Remove wheel nuts, washers and wheel.
5. Slide the wheel hub out from the bearing carrier and
3. Remove the cotter pin q, castle nut w and washers drive shaft.
e. 6. Remove the upper and lower A-arm fasteners from
the bearing carrier t. 7
7. Remove the bearing carrier. Inspect the bearing

again for smoothness and side to side movement,
replace as needed.
FINAL DRIVE
DISASSEMBLY ASSEMBLY
1. Remove the retaining ring from the bearing carrier 1. Thoroughly clean the bearing carrier housing e and
q. prepare the bearing w and retaining ring q for
assembly.
2. From the back side, tap on the outer bearing race

with a drift punch in the reliefs as shown. 2. Support the bottom of the bearing carrier housing.
Start the bearing r in the bearing carrier housing t.
NOTE Use an arbor press to install the bearing.
Drive bearing out evenly by tapping on outer race only.
Once bearing is at bottom of casting, support casting on
outer edges so bearing can be removed.
3. Inspect the bearing.
NOTE
down movement and minimal movement sideways
between inner and outer race.
4. Inspect bearing housing for scratches, wear or

damage. Replace housing if damaged.
5. Replace the bearing carrier bushings if worn or
damaged.
FINAL DRIVE
3. Press the bearing into place until the outer bearing INSTALLATION
race bottoms in housing. 1. Place the bearing carrier over the drive shaft.
CAUTION 2. Align the bottom of the bearing carrier with the lower
Use an arbor and press only on the outer race, as A-arm. If previously removed, install new lower A-
bearing damage may occur. arm bushings. Install the lower bearing carrier
fastener.
3. With the drive shaft placed in the bearing carrier,
align the top of the bearing carrier with the upper A-
arm. If previously removed, install new upper A-arm
bushings. Install the upper bearing carrier fastener.
4. Install a new retaining ring into the bearing carrier

groove.
NOTE
The lower shock bolt may need to be removed to allow
the upper A-arm to move freely.
7
4. Torque the upper and lower bearing carrier fasteners
to specification.
TORQUE
40 ft-lbs (54 Nm)
5. Install the wheel hub assembly onto the rear drive

shaft.
6. Install the washers (domed side out) e and the
wheel hub castle nut w.
FINAL DRIVE
7. Install the wheel, washers t and wheel nuts r.

Torque wheel nuts to specification.
TORQUE
Steel Wheel Nuts:
36 ft-lbs (49 Nm)
30 ft-lbs + 90º (41 Nm + 90º)
8. Carefully lower the vehicle. Torque the rear hub

castle nut to specification. Install a new cotter pin q.
TORQUE
Rear Hub Castle Nut:
110 ft-lbs (150 Nm)
FINAL DRIVE
REAR DRIVE SHAFT

REAR DRIVE SHAFT REMOVAL 5. Remove the rear drive shaft using short, sharp jerks
1. Perform the “REAR BEARING CARRIER - Removal” to free the circlip from the transmission.
procedure, steps 1-5.
2. Remove the lower shock fastener q to free the
upper A-arm.
6. Refer to the “DRIVE SHAFT SERVICE” section if

repairing the drive shaft.
REAR DRIVE SHAFT INSTALLATION

3. Remove the upper bearing carrier fastener and
separate the bearing carrier from the upper A-arm. 1. Install a new circlip q on the end of the drive shaft
and apply an anti-seize compound to the splines.
4. Carefully slide the drive shaft out by pulling the

bearing carrier outward and tipping it down to 2. Align the splines of the drive shaft with the
remove the shaft. transmission and reinstall the drive shaft. Use a
rubber mallet to tap on the outboard end of the drive
shaft if necessary.
3. Install the drive shaft into the rear bearing carrier.
4. Perform the “REAR BEARING CARRIER -
Installation” procedure to properly reassemble the
vehicle.
FINAL DRIVE
DRIVE SHAFT SERVICE

DRIVE SHAFT / CV JOINT HANDLING TIPS 2. Remove the large end of the boot from the CV joint
Care should be exercised during drive shaft removal or and slide the boot down the shaft.
when servicing CV joints. Drive shaft components are
precision parts.
Cleanliness and following these instructions is very
important to ensure proper shaft function and a normal
service life.
• The complete drive shaft and joint should be handled
by getting hold of the interconnecting shaft to avoid
disassembly or potential damage to the drive shaft
joints.
• Over-angling of joints beyond their capacity could
result in boot or joint damage.
• Make sure surface-ground areas and splines of shaft
are protected during handling to avoid damage.
• Do not allow boots to come into contact with sharp
edges or hot engine and exhaust components.
• The drive shaft is not to be used as a lever arm to
position other suspension components. 3. Clean the grease from the face of the joint.
• Never use a hammer or sharp tools to remove or to
install boot clamps. 4. Place the drive shaft in a soft-jawed vise.
• Be sure joints are thoroughly clean and that the proper 5. Using a soft-faced hammer, or brass drift, strike the
amount and type of grease is used to refill when joint inner race of the joint to drive the joint off the drive
boots are replaced and when joints are cleaned. Refer shaft. Be sure to tap evenly around the joint to avoid
to text for grease capacity of CV joints and CV joint binding.
boots.
OUTER CV JOINT / BOOT REPLACEMENT

1. Using side cutters, cut away and discard the boot
clamps.
NOTE
Tap on inner race only!
FINAL DRIVE
6. Make sure the circlip is on the shaft and not left in the 9. Visually inspect the joint by tilting the inner race to
joint. one side to expose each ball. Severe pitting, galling,
play between the ball and its cage window, any
cracking or damage to the cage, pitting or galling or
chips in raceways call for joint replacement.
NOTE
Shiny areas in ball tracks and on the cage spheres are
normal. Do not replace CV joints because parts have
polished surfaces. Replace CV joint only if components
are cracked, broken, worn or otherwise unserviceable.
10. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly.
11. Slide the small boot clamp and boot (small end first)
onto the drive shaft and position the boot in it’s
groove machined in the shaft.
12. Install a NEW circlip on the end of the shaft.
7. Remove the CV boot from the shaft.
13. Grease the joint with the special CV joint grease
CAUTION provided in the boot replacement kit. Fill the cavity
behind the balls and the splined hole in the joint’s
Complete disassembly of the CV joint is NOT
inner race. Pack the ball tracks and outer face flush
recommended. The internal components are a
with grease. Place any remaining grease into the
precision fit and develop their own characteristic wear
boot.
patterns. Intermixing the internal components could
result in looseness, binding, and/or premature failure of CAUTION
the joint.
The grease provided in the replacement kit is specially
formulated for wear resistance and durability. DO NOT
NOTE use substitutes or mix with other lubricants. 7
If the grease in the joint is obviously contaminated with
water and/or dirt, the joint should be replaced. NOTE
The amount of grease that’s provided is pre-measured,
so use all the grease.
Boot Replacement Grease Requirements:

Grease Only Service Kits
PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g
Outer CV Joint Capacity:

Front - 74g / Rear - 90g
8. Thoroughly clean the joint with an appropriate

solvent and dry the joint to prevent any residual
solvent from being left in the joint upon reassembly.
FINAL DRIVE
14. Slide the joint onto the drive shaft splines and align 20. While pulling out on the CV shaft, fully extend the CV
the circlip with the lead-in chamfer on the inner race joint and slide a straight O-ring pick or a small slotted
of the joint. screw driver between the small end of the boot and
the shaft. This will allow the air pressure to equalize
in the CV boot in the position that the joint will spend
most of its life. Before you remove your instrument,
be sure the small end of the boot is in its correct
location on the shaft.
21. Install and tighten the small clamp on the boot using
the Axle Boot Clamp Tool (PU-48951 or 8700226).
15. Use a soft-faced hammer to tap the joint onto the

drive shaft until it locks into place.
16. Pull on the joint to make sure it is securely locked in
place.
17. Remove excess grease from the CV joint's external
surfaces and place the excess grease in the boot.
Axle Boot Clamp Tool
18. Pull the boot over the joint and position the boot lips PU-48951 or 8700226
into the grooves on the joint housing and shaft. Make
sure the boot is not dimpled or collapsed.
19. Install and tighten the large clamp using the Axle
Boot Clamp Tool (PU-48951 or 8700226).

PU-48951 or 8700226
FINAL DRIVE
INNER PLUNGING JOINT / BOOT 5. Using a soft-faced hammer, or brass drift, strike the
REPLACEMENT inner race of the joint to drive the joint off the drive
shaft. Be sure to tap evenly around the joint to avoid
1. Using a side cutters, cut away and discard the boot binding.
clamps.
NOTE
Tap on inner race only!
2. Remove the large end of the boot from the plunging

joint and slide the boot down the shaft.
6. Make sure the circlip q is still on the shaft and not

left in the joint.
3. Clean the grease from the face of the joint.

4. Place the drive shaft in a soft-jawed vise.
FINAL DRIVE
7. Remove the boot from the shaft. 13. Grease the joint with the special CV joint grease
provided in the boot replacement kit. Fill the cavity
CAUTION behind the balls and the splined hole in the joint’s
Complete disassembly of the plunging joint is NOT inner race. Pack the ball tracks and outer face flush
recommended. The internal components are a with grease. Place any remaining grease into the
precision fit and develop their own characteristic wear boot.
patterns. Intermixing the internal components could
result in looseness, binding, and/or premature failure of CAUTION
the joint. The grease provided in the replacement kit is specially
formulated for wear resistance and durability. DO NOT
use substitutes or mix with other lubricants.
NOTE
If the grease in the joint is obviously contaminated with Boot Replacement Grease Requirements:
water and/or dirt, the joint should be replaced.
Grease Only Service Kits
PN 1350059 - 20g
PN 1350046 - 30g
PN 1350047 - 50g
Inner Plunging Joint Capacity:

Front - 60g / Rear - 100g
14. Fully compress the joint and push the drive shaft
firmly into the inner race.
15. Align the circlip with the lead-in chamfer.
8. Thoroughly clean the joint with an appropriate

solvent and dry the joint to prevent any residual
solvent from being left in the joint upon reassembly.
9. Visually inspect the joint for damage. Replace if
needed.
10. Clean the splines on the end of the shaft and apply a
light coat of grease prior to reassembly.
11. Slide the small boot clamp and boot (small end first)
onto the drive shaft and position the boot in its
groove machined in the shaft.
12. Install a NEW circlip on the end of the shaft. 16. Use a soft-faced hammer to tap the joint onto the
drive shaft until you reach the end of the splines and
the joint locks in place.
17. Pull on the joint to test that the circlip is seated and
that the joint is securely fastened to the shaft.
18. Remove excess grease from the plunging joint’s
external surfaces and place the excess grease in the
boot.
19. Pull the boot over the joint and position the boot lips
into the grooves on the joint housing and shaft. Make
sure the boot is not dimpled or collapsed.
FINAL DRIVE
20. Install and tighten the small clamp using the Axle DRIVE SHAFT ASSEMBLY VIEW
Boot Clamp Tool (PU-48951 or 8700226).

PU-48951 or 8700226
21. Pull out on the drive shaft to center the joint in the
housing. Slide a straight O-ring pick or a small
slotted screw driver between the large end of the
boot and the joint housing and lift up to equalize the
air pressure in the boot.
22. Position the boot lip in its groove. Install and tighten
the large clamp using the Axle Boot Clamp Tool.
7

PU-48951 or 8700226
FINAL DRIVE
PROPSHAFT U-JOINT SERVICE

REMOVAL / INSTALLATION REMOVAL / INSTALLATION (CREW)
1. Remove the PVT cover. 1. Elevate and safely support vehicle under the frame.
The use of a vehicle hoist is recommended for this
2. Remove the Drive Clutch and belt.
procedure.
3. Access the front prop shaft roll pin through the hood
opening. CAUTION
CAUTION sure machine is secure before beginning this service
Be sure machine is secure before beginning this procedure. Wear eye protection when removing
service procedure. Wear eye protection when removing bearings and seals.
pins, bearings or seals.
4. Use the Roll Pin Removal Tool to drive out the roll pin
NOTE
from the prop shaft. Prop shaft roll pin removal is only required if removing
the front portion of the prop shaft.
Roll Pin Removal Tool (PN 2872608)
2. Access the front prop shaft roll pin through skid plate
5. Slide the prop shaft back and away from front hole.
gearcase, then pull the shaft sharply forward to
remove it from the transmission shaft. 3. Use the Roll Pin Removal Tool (PN 2872608), to
drive out the roll pin from prop shaft.
6. Using care, pull the prop shaft towards the right side
of the frame and slide it out the right rear side of the Roll Pin Removal Tool (PN 2872608)
vehicle.
7. Reverse this procedure to reinstall the front prop 4. Remove the front seat base and large storage
shaft. container to access the support bearing (Item 1).
8. Use a NEW roll pin upon installation.
FRONT PROP SHAFT COMPONENTS
REF DESCRIPTION
q Grease Zerk
w Rear Yoke
e U-Joint
r Front Yoke
FINAL DRIVE
5. Remove the two nuts and bolts retaining the bearing SUPPORT BEARING REPLACEMENT
support. (CREW)
1. Follow steps 4-6 of the “Removal / Installation
(CREW)” procedure.
2. Remove the bearing support (upper and lower half)
and the retaining ring. Loosen the two set screws
retaining the bearing to the shaft.
6. Slide the rear portion of the shaft back on the

transmission shaft and move both shafts toward the
left side of the vehicle to separate them.
3. Slide the bearing off the end of the shaft.
NOTE
If bearing is seized on the shaft, remove the rear portion
of the shaft from the vehicle. Refer to “Removal / 7
Installation (CREW)”.
4. Clean the surface of the shaft and install the new

bearing.
5. Install a new retaining ring and slide the bearing tight
7. If removing the front portion of the prop shaft, slide it against the retaining ring.
back and away from front gearcase to remove it.
8. If removing the rear portion, remove the bearing
support (upper & lower half).
9. Using care, pull the rear portion of the prop shaft
towards the right side of the frame and slide it out the
right rear side of the vehicle.
10. Reverse this procedure to reinstall and assemble the
front prop shaft.
11. Torque bearing support fasteners to specification.
TORQUE
Prop Shaft Bearing Support Fasteners:
36 ft-lbs (49 Nm)
12. If front prop shaft was removed, use a NEW roll pin
upon installation.
FINAL DRIVE
6. Apply Loctite™ 242® to the set screw threads and DISASSEMBLY

torque the two bearing set screws to specification.
CAUTION
Always wear eye protection.
1. Remove internal snap ring q from all four bearing

caps.
TORQUE
Prop Shaft Bearing Set Screws:
35 in-lbs (4 Nm)
NOTE
7. Align the front and rear portions of the prop shaft as
shown below and slide them together. If yoke or bearing is removed, cross bearing must be
replaced. Note orientation of grease fitting and mark
inner and outer yoke for correct re-positioning during
installation.
2. Support inner yoke as shown and drive outer yoke

down (bearing cap out) with a suitable press.
8. Install the upper and lower halves of the bearing

support along with the two fasteners. Torque the
support bearing fasteners to specification.
TORQUE
Prop Shaft Support Bearing Fasteners:
36 ft-lbs (49 Nm)
9. Grease the prop shaft yoke(s).

10. Reinstall the large storage container and front seat
base.
FINAL DRIVE
3. Support U-joint and press inner yoke down to

remove remaining bearing caps.
4. Force U-joint cross to one side and lift out of inner

yoke.
ASSEMBLY
1. Install new bearing caps in yoke by hand. Carefully
install U-joint cross. Tighten vise or use a press to
force bearing caps in.
2. Using a suitable arbor, fully seat bearing cap in one
side. Continually check for free movement of bearing
cross as bearing caps are assembled.
3. Install snap ring to contain bearing cap just installed.
Repeat procedure for other side.
7
4. Install outer yoke, aligning marks made before
disassembly.
5. Repeat Steps 1-3 to install bearing caps on outer
yoke.
6. Seat all bearing caps against snap rings.
7. When installation is complete, yokes must pivot
freely in all directions without binding. If the joint is
stiff or binding, tap the yoke lightly to center the joint
until it pivots freely in all directions.
FINAL DRIVE
NOTES
CHAPTER 8
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
STEERING ASSEMBLY VIEW (NON-EPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
STEERING ASSEMBLY VIEW (EPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6
STEERING WHEEL REMOVAL (NON-EPS MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
STEERING SHAFT BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.8
STEERING SHAFT / STEERING RACK REMOVAL (NON-EPS MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.9
STEERING WHEEL / UPPER STEERING SHAFT REMOVAL (EPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.10
POWER STEERING UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
POWER STEERING UNIT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.11
FRONT STRUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.13
ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.13
FRONT STRUT CARTRIDGE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.13
BALL JOINT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.14
REAR A-ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.16
REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.16
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.17
ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.18
REAR STABILIZER BAR / LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.19
REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.19
ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.19
8
SHOCKS / SPRINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.20
ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.20
SHOCK REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.20
SHOCK REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.20
ITEM TORQUE VALUE

Body T-40 Screws 8 ft-lbs (11 Nm)
Bearing Carrier Fasteners 40 ft-lbs (54 Nm)
Ball Joint Fastener 30 ft-lbs (41 Nm)
Control Arm Fasteners 40 ft-lbs (54 Nm)
Seat Belt Mounting 40 ft-lbs (54 Nm)
Fasteners
Shock Mounting Bolts
40 ft-lbs (54 Nm)
(rear)
Steering Rack Mounting 16 ft-lbs (22 Nm)
Bolts
Steering Shaft to EPS 20 ft-lbs (27 Nm)
Steering Shaft to Steering 46–51 ft-lbs (62-69 Nm)
Rack
Strut Rod Retaining Nut
15 ft-lbs (21 Nm)
(Top)
Tie Rod End Jamb Nut 14 ft-lbs (19 Nm)
Tie Rod End Mounting 40 ft-lbs (54 Nm)
Nut
36 ft-lbs (49 Nm)
Wheels)
Wheel Lug Nuts 30 ft-lbs + 90º (41 Nm +
(Aluminum Wheels) 90º)
NOTE
Refer to exploded views throughout this chapter for
more torque specifications, component identification,
and location of components.
SPECIAL TOOLS
2870872 Shock Spanner Wrench
2870623 Shock Spring Compressor Tool

2876389 Multi-Function Pliers
2870871 Strut and Ball Joint Tool Set
2871573 Strut Spring Compressor (LH)
2871574 Strut Spring Compressor (RH)

or http://polaris.service-solutions.com/
Included in this machine’s tool kit, the multi-function

pliers is designed to remove the plastic push rivets used
to fasten body components.
STEERING ASSEMBLY
STEERING ASSEMBLY VIEW (NON-EPS)
REF PART DESCRIPTION NOTES

q ASM, TILT STEERING
w WHEEL, STEERING
e SHAFT, STEERING, UPPER / LOWER
r ASM, GEAR BOX, STEERING
t CAP, STEERING WHEEL
y ASM, SHOCK, OIL LOCKING
u BOLT
i BOLT 40 ft-lbs (54 Nm)
o SCREW
a BOLT
s NUT
d NUT 16 ft-lbs (22 Nm)
f NUT 40 ft-lbs (54 Nm)
g NUT 36 ft-lbs (49 Nm)
h NUT 65 ft-lbs (88 Nm)
j BUSHING, STEERING
k PIN, COTTER
l LOCTITE® 271
STEERING ASSEMBLY VIEW (EPS)
REF PART DESCRIPTION NOTES

q MOUNT, EPAS
w WHEEL, STEERING
e SHAFT, STEERING, LOWER
r SHAFT, STEERING, UPPER
t ASM, GEAR BOX, STEERING
y ASM, TILT STEERING
u ASM, POWER STEERING
i CAP, STEERING WHEEL
o ASM, SHOCK, OIL LOCKING
a BOLT
s BOLT
d BOLT 30 ft-lbs (41 Nm)
f SCREW
g BOLT
h SCREW
j BOLT
k NUT
l NUT 15 ft-lbs (21 Nm)
1( NUT 40 ft-lbs (54 Nm)
2) NUT 49 ft-lbs (66 Nm) 8

2! NUT 65 ft-lbs (88 Nm)
2@ BUSHING, STEERING
2# PIN, COTTER
2$ LOCTITE 271
STEERING WHEEL REMOVAL (NON-EPS 5. Drive the bearings out of the pivot tube using a drift
MODELS) punch.
6. Inspect the pivot tube bearing surfaces for signs of
CAUTION excessive wear or damage.
This procedure should NOT be used on EPS models. 7. Apply Loctite® 271 (Red) to the outer circumference
Using this procedure on an EPS model can of the new lower bearing race. Slide the new lower
permanently damage the EPS unit and cause a Power bearing onto the steering shaft and install the
Steering Fault. steering shaft through the pivot tube.
NOTE
1. Remove the steering wheel cap.
Use care not to allow any of the Loctite® to get in the
2. Loosen the nut and back it half way off the steering bearing.
shaft.
NOTE Be sure the lower spacers are still on the steering shaft.
If reinstalling the same steering wheel, use a white
paint marker to help align upon installation.
3. With a glove on your hand, place it under the

steering wheel. Lift upward on the inner portion of the
steering wheel while using a hammer to strike the
steering shaft nut.
4. Once the steering wheel pops loose, completely
remove the nut and lift the steering wheel off the
shaft.
5. To install:
Ensure flat washer is installed on the steering shaft and
the two wave washers above it.
6. Center the wheels and install the steering wheel so it
is properly centered on the steering shaft.
7. Install the steering wheel nut. Torque nut to REF DESCRIPTION
specification. q CAP
TORQUE w NUT
Steering Wheel Nut: e STEERING WHEEL

65 ft-lbs (88 Nm) r HUB INSERT
t BUSHING
y SHAFT, UPPER
STEERING SHAFT BEARING u TILT ASSEMBLY
REPLACEMENT
8. Apply Loctite® 271 (Red) to the outer circumference
NOTE of the new upper bearing race. Slide the new upper
bearing onto the steering shaft and press it into the
Replacement pivot tube assembly comes with new pivot tube by hand.
upper and lower bearings installed. Use this procedure
if replacing just the bearings only. NOTE
Use care not to allow any of the Loctite® to get in the
1. Perform the “Steering Shaft Removal” procedure. bearing.
2. Remove the steering wheel cap and retaining nut. Bearings will be seated in the pivot housing upon
tightening the steering wheel nut in step 14.
3. Press steering shaft out of the steering wheel and
pivot tube.
9. Install the steering wheel and hand tighten the nut.
4. Note the order and location of the spacers between
the pivot tube and steering shaft.
10. Reinstall the steering shaft assembly in the vehicle. 4. Remove the steering shaft, pivot tube and steering
Install the lower portion of the steering shaft onto the wheel from the vehicle as an assembly.
steering gear box assembly. Torque the lower pinch
bolt to specification.
TORQUE
Steering Gear Box Pinch Bolt:
35 lb-ft (47 Nm)
11. Install the fastener retaining the steering wheel tilt

assembly to the frame. Torque fastener to
specification.
TORQUE
Steering Wheel Tilt Assembly Fasteners:
40 lb-ft (54 Nm)
12. Be sure the front wheels are facing straight forward. 5. Remove the cotter pin t and then remove the
Remove the steering wheel and align as needed. fasteners y retaining the both tie rod ends to the
Torque the steering wheel nut to specification. steering knuckle.
TORQUE
Steering Wheel Nut:
65 lb-ft (88 Nm)
13. Wipe the pivot tube clean of any excess Loctite®.

14. Install steering wheel cap and field test steering
operation.
STEERING SHAFT / STEERING RACK

REMOVAL (NON-EPS MODELS)
1. Remove the pinch bolt w retaining the lower portion
of the steering shaft e to the steering rack assembly
8
q. 6. Remove the five fasteners u retaining the steering
rack to the frame.
2. Remove upper and lower dash panels.

3. Remove the steering wheel tilt assembly fasteners.
7. Reverse procedure for installation. Torque fasteners 3. Remove the steering tilt assembly fasteners.
to specification.
TORQUE
Steering Rack Mounting Bolts:
16 ft-lbs (22 Nm)
Floor Access Panel Screws

8 ft-lbs (11 Nm)
Steering Pivot Assembly to Frame Fasteners:

40 ft-lbs
Steering Wheel Nut:

65 ft-lbs (88 Nm)
4. Remove the fastener retaining the upper steering
shaft to the power steering unit.
Steering Shaft to Steering Rack Fasteners:
46–51 ft-lbs (62-69 Nm) 5. Remove the steering wheel, upper steering shaft and
pivot out as an assembly.
6. Remove the steering wheel cap.
STEERING WHEEL / UPPER STEERING
SHAFT REMOVAL (EPS)
1. Remove upper and lower dash panels (See Body /
Frame chapter).
CAUTION
Striking the steering wheel or steering shaft while
installed in the vehicle can permanently damage the
EPS unit and cause a Power Steering Fault.
2. Remove the pinch bolt retaining the upper steering

shaft to the power steering unit.
7. Loosen the nut and back it half way off the steering
shaft.
8. Place the assembly in a vise.
9. Using a large bronze drift and hammer, strike
steering shaft nut to pop the steering wheel off the
tapered shaft.
10. Once the steering wheel pops loose, completely
remove the nut and lift the steering wheel off the
shaft.
POWER STEERING UNIT REMOVAL POWER STEERING UNIT INSTALLATION

1. Remove upper steering shaft and steering wheel 1. Install the power steering unit onto the mount bracket
(See Steering Wheel / Upper Steering Shaft and torque power steering mounting bolts to
Removal (EPS), page 8.10). specification.
2. Using a 15 mm socket, remove the fastener TORQUE
qretaining the lower steering shaft to the power EPS Unit Mount Bolts:
steering unit.
30 lb-ft (41 Nm)
2. Align the skip-tooth spline on the power steering

output shaft with the opening in the lower power
steering shaft.
3. Install power steering to mount assembly and torque
TORQUE
EPS Unit Frame Bolts:
14 lb-ft (19 Nm)
4. Install the pinch bolt retaining the lower power

steering shaft to the power steering unit. Torque to
specification.
3. Remove the four fasteners w retaining the power
steering mount to the power steering unit. TORQUE
EPS Unit Pinch Bolts:
15 lb-ft (20 Nm)
5. Position the steering wheel, pivot tube and upper

steering shaft assembly to the proper mounting
location.
6. Be sure the front wheels are pointing straight ahead
and that the steering wheel is straight. Align the skip-
tooth spline q on the power steering input shaft with
8
the opening w in the upper steering shaft and install
the upper shaft onto the power steering input shaft.
WARNING
Electronic Power Steering (EPS) units are not
interchangeable between ATV and RANGER product
lines.
7. Loosely install the steering tilt assembly bolts and

nuts.
CAUTION
Striking the steering wheel or steering shaft can
permanently damage the EPS unit and cause a Power
Steering Fault.
8. Install the upper steering shaft pinch bolt and torque

to specification.
TORQUE
EPS Unit Pinch Bolts:
15 lb-ft (20 Nm)
9. Install the fastener retaining the steering wheel tilt

assembly to the frame. Torque fastener to
specification.
TORQUE
Steering Wheel Tilt Assembly Fasteners:
40 lb-ft (54 Nm)
10. Reconnect both electrical harnesses onto the power

steering unit. Be sure the connectors snap into place
and the wires are routed correctly.
11. Reinstall the upper and lower dash panels making
sure to reconnect the instrument cluster, both 12V
outlets and all the switches.
12. Turn the key switch on and test EPS operation.
FRONT STRUT
ASSEMBLY VIEW

Nut
q 13–17 ft-lbs (18–23 Nm) d Washers
8
w Washer f Ball Joint
e Rubber Spacer g Screws
r Upper Pivot Ball h Ball Joint Bracket

Spacer
t j Retaining Ring
15 ft-lbs ( 20 Nm)
y Lower Pivot Ball k Wheel Bearing
u Spring Retainer l Hubstrut
i Spring 1( Cam Adjuster
o Bumper 2) Washer
a Spacer 2! Front Strut

Nut
s Bolts 2@ 20 ft-lbs (27 Nm)
FRONT STRUT CARTRIDGE 2. Compress spring using strut spring compressor

REPLACEMENT tools.
1. Hold strut rod and remove top nut. Strut Spring Compressor Tools
(PN 2871573) and (PN 2871574)
3. Remove upper strut pivot assembly. 7. Using ball joint removal/installation tool kit (PN
2870871), remove ball joint from strut housing.
4. Remove coil spring and collapse strut cartridge.
• Install puller guide t with extension cap y.
5. Remove two pinch bolts from strut casting. • Apply grease to extension cap and threads of puller
6. Remove strut cartridge. bolt to ease removal.
• Thread bolt u with nut i onto ball joint stud as shown.
7. Install cartridge until bottomed in strut casting. • Apply heat to ease removal.
8. Install pinch bolts with wire clamp (s) and torque to • Hold bolt and turn nut clockwise until ball joint is
specification. removed from strut housing.
TORQUE
Strut Pinch Bolt:
26 ft-lbs. (35 Nm)
9. Reassemble spring and top pivot assembly. Be sure

all parts are installed properly and seated fully.
10. Torque strut rod nut to specification. Do not over
torque nut.
TORQUE
Strut Mounting Nut (top):
15 ft-lbs (21 Nm)
BALL JOINT REPLACEMENT

1. Loosen front wheel nuts slightly. 8. To install new ball joint:
• Remove extension cap and attach puller guide using
2. Elevate and safely support machine under footrest/ short bolts provided in the kit.
frame area. • Insert new ball joint o into driver a.
CAUTION
procedure.
3. Remove wheel nuts and wheels.

4. Remove cotter pin q from ball joint castle nut.
• Slide ball joint / driver assembly into guide.

• Apply heat to ease installation.
• Drive new joint into strut housing until fully seated.
5. Remove castle nut w and separate A-arm from ball

joint stud e.
6. Remove screws and ball joint retaining plate r.
9. Apply Loctite™ 242 (PN 2871949) to threads of

retaining plate screws or install new screws with pre-
applied locking agent. Torque screws to
specification.
TORQUE
Ball Joint Retaining Plate Screws:
8 ft-lbs (11 Nm)
10. Install A-arm on ball joint and torque castle nut to

specification.
TORQUE
Ball Joint Nut:
30 ft-lbs (41 Nm)
11. Install new cotter pin with open ends toward rear of
machine.
REAR A-ARMS
REMOVAL / REPLACEMENT 4. Remove the fasteners attaching the upper A-arm to
The following procedure details upper and lower A-arm the frame and remove the upper A-arm from the
removal and replacement on one side of the vehicle. vehicle.
Repeat the following steps to remove the A-arm(s) from
the opposite side.
NOTE
Use the exploded view in this section as a reference
during the procedure.
1. Elevate and safely support the rear of vehicle off the

ground and remove the rear wheel.
Upper A-arm Removal
2. Remove the fastener q retaining the lower portion of
the shock and stabilizer linkage to the upper A-arm.
5. Examine A-arm and bearing carrier bushings and

pivot tubes (see “Exploded View”). Replace if worn.
Discard hardware.
WARNING
The locking agent on the existing bolts was destroyed
during removal. DO NOT reuse old hardware. Serious
injury or death could result if fasteners come loose
during operation.
6. If not replacing the A-arm, thoroughly clean the a-

arm and pivot tubes.
7. Insert new A-arm bushings and pivot tubes into the
3. Remove the fastener w attaching the upper A-arm to new A-arm.
the bearing carrier.
Lower A-arm Removal
8. Remove the fastener e attaching the lower A-arm to
the bearing carrier.
9. Remove the fasteners attaching the lower A-arm to 3. Route the brake line over the top of the lower A-arm
the frame and remove the lower A-arm from the and secure it in the retainer q.
vehicle.
4. Install upper A-arm assembly onto vehicle frame.

10. Examine A-arm and bearing carrier bushings and Torque new fasteners to specification.
pivot tubes (see “Exploded View”). Replace if worn.
Discard hardware. TORQUE
Control Arm Fasteners:
WARNING 40 ft-lbs (54 Nm)
The locking agent on the existing bolts was destroyed
during removal. DO NOT reuse old hardware. Serious 5. Attach upper A-arm to bearing carrier. Torque new
injury or death could result if fasteners come loose fastener to specification.
during operation.
TORQUE
11. If not replacing the A-arm, thoroughly clean the a- Bearing Carrier Fastener:
arm and pivot tubes. 40 ft-lbs (54 Nm)
12. Insert new A-arm bushings and pivot tubes into the
new A-arm. 6. Reinstall the lower portion of the shock and stabilizer
linkage to the upper A-arm. Torque shock / linkage
INSTALLATION fastener to specification. 8
1. Install lower A-arm assembly onto vehicle frame. TORQUE
Torque NEW fasteners to specification.
Shock / Linkage Fastener:
TORQUE 40 ft-lbs (54 Nm)
Control Arm Fasteners:
40 ft-lbs (54 Nm) 7. Install wheel and torque wheel nuts to specification.
TORQUE
2. Attach lower A-arm to bearing carrier. Torque NEW
fastener to specification. Steel Wheel Lug Nuts:
36 ft-lbs (49 Nm)
TORQUE Aluminum Wheel Lug Nuts:
Bearing Carrier Fasteners: 30 ft-lbs + 90º (41 Nm + 90º)
40 ft-lbs (54 Nm)
WARNING
Upon A-arm installation completion, test vehicle at low
speeds before putting into service.
ASSEMBLY VIEW

q Lower A-Arm y Bushing
w Upper A-Arm u Pin

e Bearing Carrier i Grease Zerk
Nuts
r Wheel Bearing o 40 ft-lbs (54 Nm)
t Snap Ring
REAR STABILIZER BAR / LINKAGE

REMOVAL / INSTALLATION ASSEMBLY VIEW
1. Elevate and safely support vehicle with weight
removed from the rear wheel(s).
2. Remove the retaining nut q from the upper portion
of the stabilizer bar linkage bushing on each side of
the vehicle.

q Lower A-Arm
w Stabilizer Bar
Linkage
3. Remove the two fasteners w that secure the
stabilizer bar to the main frame on each side. e Stabilizer Bar
4. Remove the stabilizer bar from the frame and inspect
the stabilizer bar for straightness. r Stabilizer Bar
Bushing / Shield
5. Inspect the stabilizer bar bushings and replace if
needed. t Nut Torque to 17 ft-lbs
(23 Nm)
6. Inspect the rubber bushings on the stabilizer linkage
rod and replace if needed. If replacing the stabilizer
linkage, remove the lower shock bolt from the upper
A-arm.
8
7. Reverse this procedure for installation.
8. Torque the stabilizer retaining bolts and upper rubber
bushing nuts to specification.
9. If the stabilizer linkage was removed, torque the
lower shock retaining bolt to specification.
SHOCKS / SPRINGS
ASSEMBLY VIEW SHOCK REPLACEMENT
1. Using a spring compressor, compress the shock
spring far enough to remove the spring retainer.

2. Remove the spring and adjusting cam from the
q Spring Adjuster existing shock and install components onto the new
shock.
w Spring Retainer
3. Compress the shock spring and install the spring
e Nuts Torque to 40 ft-lbs retainer.
(54 Nm)
4. Reinstall the shock onto the vehicle and torque new
SHOCK REMOVAL / INSTALLATION TORQUE
1. Elevate the vehicle off the ground to relieve the Shock Bolt Torque:
suspension load. 40 ft-lbs (54 Nm)
2. Remove the upper and lower fasteners retaining the
shock and remove the shock from the vehicle.
3. Reverse the procedure to reinstall the shock. Torque

NEW fasteners to specification.
TORQUE
Shock Fasteners:
40 ft-lbs (54 Nm)
BRAKE SYSTEM
CHAPTER 9
BRAKE SYSTEM
BRAKE SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
BRAKE SYSTEM NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
BRAKE SYSTEM SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
HYDRAULIC BRAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
BRAKE SYSTEM ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
RANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
RANGER CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7
MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
BRAKE PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
FOOT BRAKE PEDAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
PEDAL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
PEDAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
BRAKE PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10
BRAKE BLEEDING / FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.10
BRAKE BURNISHING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.11
FRONT BRAKE PADS - RANGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12
PAD REMOVAL / DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.12
PAD ASSEMBLY / INSTALLATION- RANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13 9
PAD ADJUSTMENT- RANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.13
FRONT CALIPER - RANGER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14
FRONT CALIPER ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.14
FRONT CALIPER REMOVAL- RANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15
FRONT CALIPER DISASSEMBLY - RANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.15
FRONT CALIPER INSPECTION- RANGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16
FRONT CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.16
FRONT CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.17
FRONT BRAKE PADS - CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.18
PAD REMOVAL - CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.18
PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19
PAD ASSEMBLY / INSTALLATION- CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.19
FRONT CALIPER - CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
FRONT CALIPER ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
FRONT CALIPER REMOVAL- CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.21
FRONT CALIPER DISASSEMBLY - CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.22
BRAKE SYSTEM
FRONT CALIPER INSPECTION - CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.23

FRONT CALIPER ASSEMBLY - CREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.24
FRONT CALIPER INSTALLATION - CREW. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.24
FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.26
DISC INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.26
DISC REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.27
REAR BRAKE PAD SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.28
PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.28
BRAKE PAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.29
REAR PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.29
REAR CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.30
CALIPER ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.30
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.31
REAR CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.31
REAR CALIPER INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.32
REAR CALIPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.32
REAR CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.33
REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.34
DISC RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.34
BRAKE DISC INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.34
DISC REMOVAL / REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.35
PARKING BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.36
PARKING BRAKE ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.36
PARKING BRAKE CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.38
PARKING BRAKE CALIPER EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.38
PARKING BRAKE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.38
CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.38
CALIPER DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.39
NEW BRAKE PAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.40
PARKING BRAKE CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.41
PARKING BRAKE DISC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.43
DISC INSPECTION / REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.43
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.44
BRAKES SQUEAL / POOR BRAKE PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.44
PEDAL VIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.44
CALIPER OVERHEATS (BRAKES DRAG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.44
BRAKES LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9.44
BRAKE SYSTEM
GENERAL INFORMATION
BRAKE SERVICE SPECIFICATIONS
FRONT BRAKE
Front Brake Pad Thickness 0.298 ± .007" / 7.56 ± .178 mm 0.030" (.76 mm)
Front Brake Disc Thickness 0.158" (4.01 mm) 0.140" (3.56mm)
Front Brake Disc Runout - 0.010" (.254mm)
REAR BRAKE
Rear Brake Pad Thickness 0.298 ± .007"/ 7.56 ± .178 mm 0.030" (.76 mm)
Rear Brake Disc Thickness 0.188" (4.78 mm) 0.170" (4.32 mm)
Rear Brake Disc Runout - 0.010" (.254 mm)
ITEM TORQUE
Bleeder Screws 47 in-lbs (5 Nm)
18 ft-lbs (25 Nm)
(Front)
27 ft-lbs (36 Nm)
(Rear)
Brake Line Banjo Bolts 15 ft-lbs (20 Nm)
Brake Line Flare Fittings 14 ft-lbs (19 Nm)
Brake Switch 15 ft-lbs (20 Nm)

Caliper Mounting Bolts 46 ft-lbs (62 Nm)
Hub Nut (front) 90 ft-lbs (122 Nm)
9
Hub Nut (rear) 110 ft-lbs (150 Nm)
Master Cylinder Mount 17 ft-lbs (23 Nm)
Bolts
SPECIAL TOOLS
Mity Vac™ Pressure Test
2870975
Tool

BRAKE SYSTEM
BRAKE SYSTEM NOTES

BRAKE SYSTEM SERVICE NOTES
Disc brake systems are light weight, low maintenance, and perform well in the conditions this vehicle will routinely
encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to
ensure proper system function and maximum pad service life.
• Optional pads are available to suit conditions in your area. Select a pad to fit riding style and environment.
• Do not over-fill the master cylinder fluid reservoir.
• Make sure the brake pedal returns freely and completely.
• Adjust stop pin on front caliper after pad service.
• Check and adjust master cylinder reservoir fluid level after pad service.
• Make sure atmospheric vent on reservoir is unobstructed.
• Test for brake drag after any brake system service and investigate cause if brake drag is evident.
• Make sure caliper moves freely on guide pins (where applicable).
• Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely.
• Perform a brake burnishing procedure after installing new pads to maximize service life.
• DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only approved brake
cleaning products.
BRAKE NOISE TROUBLESHOOTING

Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration).
If cleaning does not reduce the occurrence of brake noise, Permatex™ Disc Brake Quiet is commercially available,
and can be applied to the back of the pads. Follow directions on the package. This will keep pads in contact with
caliper piston(s) to reduce the chance of squeaks caused by dirt or dust.
BRAKE NOISE TROUBLESHOOTING

POSSIBLE CAUSE REMEDY
Spray disc and pads with CRC Brakleen™ or an
equivalent non-flammable aerosol brake cleaner.
Dirt, dust, or imbedded material on pads or disc
Remove pads and/or disc hub to clean imbedded
material from disc or pads.
Pad(s) dragging on disc (noise or premature pad wear) Adjust pad stop (front calipers)
because of improper adjustment
Master cylinder reservoir overfilled Set to proper level
Master cylinder compensating port restricted Clean compensating port
Master cylinder piston not returning completely Inspect. Repair as necessary
Caliper piston(s) not returning Clean piston(s) seal
Operator error (riding the brake) Educate operator
Loose wheel hub or bearings Check wheel and hub for abnormal movement.
Brake disc warped or excessively worn Replace disc
Brake disc misaligned or loose Inspect and repair as necessary
If noise does not change when brake is applied check
Noise is from other source (axle, hub, disc or wheel)
other sources. Inspect and repair as necessary
Wrong pad for conditions Change to a softer or harder pad
BRAKE SYSTEM
HYDRAULIC BRAKE SYSTEM OPERATION

The brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake
lines, brake calipers, brake pads, and brake discs, which are secured to the drive line.
When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the
master cylinder piston moves inward it closes a small opening (compensating port) within the cylinder and starts to
build pressure within the brake system. As the pressure within the system is increased, the pistons located in the brake
calipers move outward and apply pressure to the moveable brake pads. These pads contact the brake discs and move
the calipers in their floating bracket, pulling the stationary side pads into the brake discs. The resulting friction reduces
brake disc and vehicle speed.
The friction applied to the brake pads will cause the pads to wear. As these pads wear, the piston within the caliper
moves further outward and becomes self adjusting. Fluid from the reservoir fills the additional area created when the
caliper piston moves outward.
Brake fluid level is critical to proper system operation. Too little fluid will allow air to enter the system and cause the
brakes to feel spongy. Too much fluid could cause brakes to drag due to fluid expansion.
Located within the master cylinder is the compensating port which is opened and closed by the master cylinder piston
assembly. As the temperature within the hydraulic system changes, this port compensates for fluid expansion or
contraction. Due to the high temperatures created within the system during heavy braking, it is very important that the
master cylinder reservoir have adequate space to allow for fluid expansion. Never overfill the reservoir! Do not fill
the reservoir beyond the MAX LEVEL line!
When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189).
WARNING
Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or
use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture. This causes the
boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of serious injury.
BRAKE SYSTEM
BRAKE SYSTEM ASSEMBLY VIEW

RANGER

q Master Cylinder
w Banjo Bolt Torque to 15 ft-lbs (20 Nm)
e Caliper Mounting Bolts Torque to 46 ft-lbs (62 Nm)
r Pad Adjuster Screw Torque to 48 ft-lbs (5.5 Nm)
t Brake Line Fastener Bolt Torque to 15 ft-lbs (20 Nm)
y Screw Torque to 12–15 ft-lbs (16–20 Nm)
BRAKE SYSTEM
RANGER CREW

q Master Cylinder
w Banjo Bolt Torque to 15 ft-lbs (20 Nm)
e Caliper Mounting Bolts Torque to 46 ft-lbs (62 Nm)
r Pad Adjuster Screw Torque to 48 ft-lbs (5.5 Nm)
t Brake Line Fastener Bolt Torque to 15 ft-lbs (20 Nm)
y Screw Torque to 12–15 ft-lbs (16–20 Nm)

9
BRAKE SYSTEM
MASTER CYLINDER
REMOVAL 5. Loosen the brake line banjo bolts r and allow the
1. Remove the retaining clip q from the clevis pin w fluid to drain.
that attaches the master cylinder to the brake pedal NOTE
lever.
Make note of front and rear brake line orientation on the
2. Remove LH wheel well panel to access master master cylinder.
cylinder.
6. Dispose of brake fluid properly and do not re-use.
INSTALLATION
Reverse Steps 1-5 for master cylinder installation. Refer
to the torque specifications in the illustration.
BRAKE PRESSURE SWITCH

The brake pressure switch q is located on the front
brake line outlet on the master cylinder.
3. Remove the two mounting bolts e that secure the

master cylinder to the frame.
4. Remove master cylinder and place a fluid catch
container under the master cylinder brake line banjo
bolt r.
TORQUE
Brake Pressure Switch / Banjo Bolt:
15 ft-lbs (20 Nm)
NOTE
Always replace banjo washers if fastener is loosened or
removed.
e Mounting Bolts Torque to 15 ft-lbs
(20 Nm)
r Banjo Bolts Torque to 15 ft-lbs

(20 Nm)
CAUTION
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact with finished

surfaces.
BRAKE SYSTEM
FOOT BRAKE PEDAL

PEDAL REMOVAL
1. Remove the retaining clip q and clevis pin w from
the master cylinder e to free it from the brake pedal
r.
2. Remove the brake pedal pivot fastener and bushings

t off the mount bracket.
PEDAL INSTALLATION
1. Reverse steps for foot brake installation.
2. Tighten pivot bolt sufficiently. Refer to the general
torque specifications in Chapter 1.
BRAKE SYSTEM
BRAKE PROCEDURES
BRAKE BLEEDING / FLUID CHANGE 6. Install a box-end wrench on caliper bleeder screw w.
NOTE
When bleeding the brakes or replacing the fluid always
start with the furthest caliper from the master cylinder.
CAUTION
Always wear safety glasses.
CAUTION
Brake fluid will damage finished surfaces. Do not allow
brake fluid to come in contact with finished surfaces.
1. Locate master cylinder reservoir under the hood.

Clean reservoir cover thoroughly. 7. Attach a tight-fitting, clear hose to the bleeder fitting.
2. Remove cover from reservoir. 8. Place a small amount of fresh brake fluid into a
small, clear container and place the other end of
3. If changing fluid, remove old fluid from reservoir with bleeder hose into the container.
a Mity Vac™ pump or similar tool.
9. Have an assistant slowly pump the brake pedal until
Mity Vac™ (PN 2870975) pressure builds and then hold.
10. Quickly open and close the bleed screw while
4. Add brake fluid to the indicated MAX level q of holding pressure on the brake pedal.
reservoir.
NOTE
Do not release brake pedal before bleeder screw is
tight or air may be drawn into master cylinder.
11. Release brake pedal pressure. Check level of fluid in

reservoir and add if necessary (Figure 1-6).
12. Repeat Steps 9, 10, and 11 until brake pedal is firm
and no air can be seen moving through the clear
hose. Add fluid as necessary to maintain level in
reservoir.
Master Cylinder Fluid Level
Between the MIN and MAX line
CAUTION
Polaris DOT 4 Brake Fluid
(P/N 2872189) Maintain at least 1/2"(1.27 cm) of brake fluid in the
reservoir to prevent air from entering the master
cylinder.
5. Begin bleeding procedure with caliper furthest from
master cylinder.
13. Tighten bleeder screw and remove bleeder hose.
Torque bleeder screw to specification.
TORQUE
Bleeder Screw:
47 in-lbs (5.3 Nm)
14. Repeat Steps 9 - 13 for the remaining brake calipers.
BRAKE SYSTEM
15. Install master cylinder reservoir cover.

16. Field test machine at low speed before putting into
service. Check for proper braking action and pedal
reserve. With pedal firmly applied, pedal reserve
should be no less than 1/2"(1.3 cm).
17. Check brake system for fluid leaks.
BRAKE BURNISHING PROCEDURE

It is required that a burnishing procedure be performed
after installation of new brake pads to extend service life
and reduce noise.
Test drive machine and slowly increase speed to above
20 mph. Gradually apply brakes to stop machine. Allow
pads and disc to cool sufficiently during the procedure.
Do not allow pads or disc to become hot or warping may
result. Repeat this procedure 10 times to maximize pad
service life.
BRAKE SYSTEM
FRONT BRAKE PADS - RANGER 5. Push upper pad retainer pin e inward and slip outer
brake pad past edge. Remove the pad.
PAD REMOVAL / DISASSEMBLY
1. Elevate and support front of machine.
CAUTION
Use care when supporting vehicle so that it does not tip
or fall. Severe injury may occur if machine tips or falls.
2. Remove the front wheel. Loosen pad adjuster screw

q 2-3 turns.
BRAKE PAD INSPECTION

looseness.
wear.
3. Remove the two caliper bolts w and caliper from

mounting bracket.
4. Push caliper piston into caliper bore slowly using a
C-clamp or locking pliers with pads installed.
MEASUREMENT
Brake Pad
.030″ (0.762 mm)
NOTE
Brake fluid will be forced through compensating port
into master cylinder fluid reservoir when piston is
pushed back into caliper. Remove excess fluid from
reservoir as required.
BRAKE SYSTEM
PAD ASSEMBLY / INSTALLATION- RANGER PAD ADJUSTMENT- RANGER

1. Lubricate mounting bracket pins (Item 1) with a light 1. Install the adjuster screw (Item 1) and turn clockwise
film of disc brake caliper lube, and install rubber dust until stationary pad contacts disc, then back off 1/2
boots (Item 2). turn (counterclockwise).
2. Compress mounting bracket and make sure dust 2. Be sure fluid level in reservoir is up to MAX line
boots are fully seated. Install pads with friction inside reservoir and install reservoir cap.
material facing each other. Be sure pads and disc
are free of dirt or grease. Master Cylinder Fluid
Up to MAX line inside reservoir
3. Install caliper on hub strut, and torque mounting bolts
(Item 3) to specification.
3. Install wheels and torque wheel nuts.
4. It is recommended that a burnishing procedure be
performed after installation of new brake pads to
extend service life and reduce noise. Start machine
and slowly increase speed to 30 mph. Gradually
apply brakes to stop machine. Repeat procedure 10
times.
TORQUE
Steel Wheel Lug Nuts:
36 ft-lbs (49 Nm)
30 ft-lbs + 90º (41 Nm + 90º) 9
TORQUE
Front Caliper Mounting Bolts:
46 ft-lbs (62 Nm)
4. Slowly pump the brake pedal until pressure has been

built up. Maintain at least 1/2"(12.7 mm) of brake
fluid in the reservoir to prevent air from entering the
brake system.
BRAKE SYSTEM
FRONT CALIPER - RANGER

FRONT CALIPER ASSEMBLY VIEW

q Adjuster Screw Finger Tighten
w Bleeder Screw 30–60 in-lbs (3.4–6.8 Nm)
e Caliper Body
r Square O-Rings Apply Polaris Dot 4 Brake Fluid
t Piston Apply Polaris Dot 4 Brake Fluid
y Dust Boots
u Caliper Bracket
i Caliper Pins Apply Brake Disc Caliper Lube
o Pads
BRAKE SYSTEM
FRONT CALIPER REMOVAL- RANGER FRONT CALIPER DISASSEMBLY - RANGER

1. Elevate and support front of machine. 1. Remove brake pad adjuster screw (Item 1).
CAUTION 2. Push upper pad retainer pin inward and slip brake
pads past edge, if pads are still installed.
or fall. Severe injury may occur if machine tips or falls. 3. Remove mounting bracket (Item 2) and dust boot
(Item 3)
2. Remove the front wheel.
3. Remove brake line from the caliper. Place a
container under caliper to catch fluid draining from
brake line.
4. Remove piston (Item 4) and square O-rings (Item 5)

from the caliper body (Item 6).
4. Remove brake caliper mounting bolts and caliper.
9
5. Clean the caliper body, piston, and retaining bracket
with brake cleaner or alcohol.
NOTE
Be sure to clean seal grooves in caliper body.
BRAKE SYSTEM
FRONT CALIPER INSPECTION- RANGER FRONT CALIPER ASSEMBLY

1. Inspect caliper body for nicks, scratches or wear. 1. Install new square O-rings q in the caliper body. Be
Measure bore size and compare to specifications. sure that the grooves are clean and free of residue or
Replace if damage is evident or if worn beyond brakes may drag.
service limit.
2. Coat the piston with clean Polaris DOT 4 Brake Fluid

(P/N 2872189). Install piston w with a twisting
MEASUREMENT
motion while pushing inward. Piston should slide in
Front Caliper Piston Bore I.D.: and out of bore smoothly, with light resistance.
Std. 1.5050-1.5040” (32.27-30.202 mm)
3. Lubricate the mounting bracket pins with disc brake
Service Limit 1.5060” (38.252 mm) caliper lube, and install the rubber dust seal boots.
2. Inspect piston for nicks, scratches, wear or damage. CAUTION
Measure diameter and replace if damaged or worn
Do not allow grease to come into contact with the piston
beyond service limit.
and seals.
Damage may occur to the components.
MEASUREMENT
Front Caliper Piston O.D.:
4. Compress the mounting bracket and make sure the
Std. 1.4985-1.5000” (38.062 - 38.10 mm) dust seals are fully seated. Install the brake pads.
Service Limit 1.4980” (38.049 mm) Clean the disc and pads with brake parts cleaner or
denatured alcohol to remove any dirt, oil or grease.
3. Inspect the brake disc and pads as outlined for brake
pad replacement in this chapter.
BRAKE SYSTEM
FRONT CALIPER INSTALLATION

1. Install caliper on hub strut, and torque mounting bolts
q.
TORQUE
Front Caliper Mounting Bolt:
46 ft-lbs (62 Nm)
2. Install brake line and tighten securely with a flare nut

wrench.
3. Install the adjuster screw w and turn until stationary
pad contacts disc, then back off 1/2 turn.
4. Follow brake bleeding procedure outlined earlier in

this chapter.
5. Install wheels and torque wheel nuts to specification.
TORQUE
36 ft-lbs (49 Nm)
6. Burnish brake pads as outlined in this chapter
BRAKE SYSTEM
FRONT BRAKE PADS - CREW

PAD REMOVAL - CREW 4. Push caliper piston into caliper bore slowly using a
1. Elevate and support front of vehicle. C-clamp or locking pliers with pads installed.
CAUTION
or fall.
Severe injury may occur if machine tips or falls.
2. Remove the wheel nuts, washers and front wheel.

Loosen pad adjuster screw (Item 1) 2-3 turns.
NOTE
3. Remove the upper and lower caliper mounting bolts 5. Push mounting bracket inward and slip outer brake
and remove the caliper from the front hub. pad past edge. Then remove inner pad.
NOTE
When removing caliper, use care not to damage brake
line. Support caliper so to avoid kinking or bending
brake line.
BRAKE SYSTEM
PAD INSPECTION PAD ASSEMBLY / INSTALLATION- CREW

1. Measure overall thickness of brake pad with insulator 1. Lubricate mounting bracket pins with a light film of
plate. Replace pads if worn beyond the service limit. disc brake caliper lube, and install rubber dust boots.
2. Compress mounting bracket and make sure dust

MEASUREMENT boots are fully seated. Install pads with friction
Front Brake Pad Thickness: material facing each other.
New: .298 ± .007” (7.56 ± .178 mm)
Service Limit: .180” (4.6 mm) WARNING
If brake pads are contaminated with grease, oil, or
liquid soaked do not use the pads.
Use only new, clean pads.
3. Install caliper onto front hub and torque mounting

bolts.
TORQUE
Front Caliper Mount Bolt:
46 ft-lbs (62 Nm)

built up. Maintain at least 1/2, (12.7 mm) of brake
brake system.
BRAKE SYSTEM
5. Install the pad adjuster set screw (Item 1) and turn

clockwise until stationary pad contacts disc, then
back off 1/2 turn (counterclockwise).
6. Verify fluid level in reservoir is up to MAX line inside

reservoir and install reservoir cap.
Master Cylinder Fluid
Up to MAX line inside reservoir
7. Install wheel and torque wheel nuts to specification

(see “Chapter 2 - Maintenance”).
BRAKE SYSTEM
FRONT CALIPER - CREW

FRONT CALIPER ASSEMBLY VIEW

q Bleeder Screw 47 in-lbs (5.3 Nm)
w Socket Set Screw

9
e Caliper Assembly
r Dust Boots
t Square O-Rings Apply Polaris DOT 4 Brake Fluid
y Piston
u Caliper Mount
i Caliper Pins Apply Disc Brake Caliper Lube
o Brake Pads
FRONT CALIPER REMOVAL- CREW 2. Remove the four wheel nuts and the front wheel.
1. Elevate and safely support the front of the vehicle. 3. Clean caliper area before removal.
CAUTION
or fall. Severe injury may occur.
BRAKE SYSTEM
4. Place a container below the caliper to catch brake FRONT CALIPER DISASSEMBLY - CREW
fluid when removing the line. Remove brake line 1. Push brake pad retainer pin inward and slip brake
(Item 1) from caliper. pads past the edge.
5. Loosen brake pad adjustment set screw (Item 2) 2-3 2. Remove both brake pads from the caliper.
turns to allow brake pad removal after the caliper is
removed.
3. Remove mounting bracket, pin assembly and dust

boot.
6. Remove the two caliper mounting bolts and remove
the caliper assembly from the front strut.
4. Thoroughly clean the brake caliper before

disassembly and prepare a clean work area to
disassemble the caliper.
BRAKE SYSTEM
5. While holding the caliper and covering the pistons FRONT CALIPER INSPECTION - CREW
with a shop towel, carefully apply compressed air to 1. Inspect caliper body for nicks, scratches, pitting or
the brake line inlet to force the pistons out from the wear. Measure bore size and compare to
caliper. specifications. Replace if damaged or worn beyond
service limit.
CAUTION
Use caution and always wear safety glasses when
working with compressed air.
NOTE
Do not remove the caliper pistons with a pliers. The
piston sealing surfaces will become damaged if a pliers
is used.
6. Once the pistons are removed, use a pick to carefully

remove the square O-rings from the caliper. O-rings
should be replaced during caliper service.
MEASUREMENT
Caliper Piston Bore I.D.:
Std: 1.373” (34.87 mm)
2. Inspect piston for nicks, scratches, pitting or wear.

Measure piston diameter and replace if damaged or
worn beyond service limit.

MEASUREMENT
Caliper Piston O.D.:
Std: 1.370” (34.80 mm)
3. Inspect the brake disc and pads as outlined in this

NOTE chapter.
BRAKE SYSTEM
FRONT CALIPER ASSEMBLY - CREW FRONT CALIPER INSTALLATION - CREW

1. Install new O-rings (Item 1) in the caliper body. Be 1. Install caliper and torque mounting bolts to
sure the grooves (Item 2) are clean and free of specification.
residue or brakes may drag upon assembly.
2. Coat pistons with clean Polaris DOT 4 Brake Fluid. TORQUE

Install pistons with a twisting motion while pushing Front Caliper Mount Bolt:
inward. Piston should slide in and out of bore 46 ft-lbs (62 Nm)
smoothly, with light resistance.
3. Lubricate the mounting bracket pins with disc brake 2. Install brake line and torque the banjo bolt (Item 1) to
caliper lube, and install the rubber dust seal boots. the proper torque specification.

dust seal boots are fully seated. Install the brake
pads. Clean the disc and pads with brake parts
cleaner or denatured alcohol to remove any dirt, oil
or grease.
BRAKE SYSTEM
3. Install the pad adjustment screw (Item 2) and turn

until stationary pad contacts disc, then back off 1/2
turn.
4. Perform brake bleeding procedure as outlined earlier

in this chapter.
5. Install wheel and torque wheel nuts to specification
(see Chapter 2).
NOTE
If new brake pads are installed, brake burnishing is
required. SeeBrake Burnishing Procedure, page 9.11.
BRAKE SYSTEM
FRONT BRAKE DISC

DISC INSPECTION 3. Mount dial indicator as shown to measure disc
1. Visually inspect the brake disc for nicks, scratches, runout. Slowly rotate the disc and read total runout
or damage. on the dial indicator. Replace the disc if runout
exceeds specifications.
2. Measure the disc thickness at 8 different points
around the pad contact surface using a 0-1"
micrometer. Replace disc if worn beyond service
limit.
MEASUREMENT
Brake Disc Runout:
Service Limit .010” (.254 mm)
MEASUREMENT
Brake Disc Thickness:
New .150-.165” (3.81 - 4.19 mm)
Service Limit .140”/3.56 mm
MEASUREMENT
Brake Disc Thickness Variance:
Service Limit .002” (.051 mm)
difference between measurements
BRAKE SYSTEM
DISC REMOVAL / REPLACEMENT

1. Remove bolts q and disc w.
2. Clean mating surface of disc and hub e.

3. Install disc on hub.
4. Apply Loctite® 272 to new bolts, install and tighten to
specification.
TORQUE
Front Brake Disc Mounting Bolts:
18 ft-lbs (25 Nm)
BRAKE SYSTEM
REAR BRAKE PAD SERVICE

PAD REMOVAL 5. Push caliper piston into caliper bore slowly with pads
1. Elevate and support rear of machine. installed.
NOTE
CAUTION
2. Remove the rear wheel. Loosen pad adjuster screw
q 2-3 turns. 6. Remove the brake pads.
3. Clean caliper area before removal.

4. Remove caliper mounting bolts w and lift caliper off
of disc.
CAUTION
When removing caliper, be careful not to damage brake
line. Support caliper so as not to kink or bend brake
line.
BRAKE SYSTEM
BRAKE PAD INSPECTION REAR PAD INSTALLATION

1. Install new pads in caliper body.
looseness.
wear.
2. Install caliper and torque mounting bolts.
MEASUREMENT
Brake Pad
.030″ (0.762 mm)
TORQUE
Rear Brake Caliper Mounting Bolts:
46 ft-lbs (62 Nm)
9
3. Turn adjuster screw back in finger tight using a hex
wrench. Then back off 1/2 turn.
built up. Maintain at least 1/2"(12.7 mm) of brake
master cylinder.
5. Fill master cylinder to Max level.
6. Burnish brakes as outlined in this chapter.
BRAKE SYSTEM
REAR CALIPER
CALIPER ASSEMBLY VIEW

q Socket Set Screw
w Bleeder Screw 47 in-lbs (5.3 Nm)
e Caliper Assembly
r Dust Boots
t Square O-Rings Apply Polaris DOT 4 Brake Fluid
y Piston Apply Polaris DOT 4 Brake Fluid
u Caliper Pins Apply Disc Brake Caliper Lube
i Caliper Mount
o Brake Pads
BRAKE SYSTEM
CALIPER REMOVAL REAR CALIPER DISASSEMBLY

1. Safely support the rear of the machine. 1. Remove brake pad adjuster screw q.
2. Push upper pad retainer pin inward and slip brake
CAUTION pads u past edge, if pads are still installed.
3. Remove mounting bracket w and dust boot e.
2. Use a wrench to remove the brake line. Place a

container to catch brake fluid draining from brake
lines.
4. Remove piston r and square O-rings t from the

caliper body y.
3. After the fluid has drained into the container, remove

the two caliper mounting bolts and remove caliper.
9
NOTE
4. Clean disc, caliper body, and pistons with brake
cleaner or alcohol.
BRAKE SYSTEM
REAR CALIPER INSPECTION REAR CALIPER ASSEMBLY

1. Inspect caliper body for nicks, scratches or wear. 1. Install new square O-rings q in the caliper body. Be
Measure bore size and compare to specifications. sure that the grooves are clean and free of residue or
Replace if damage is evident or if worn beyond brakes may drag.
service limit.
2. Coat the piston with clean DOT 4 Brake Fluid (PN

2872189). Install piston w with a twisting motion
MEASUREMENT
while pushing inward. Piston should slide in and out
Caliper Piston Bore I.D.: of bore smoothly, with light resistance.
Std: 1.505” (38.23 mm)
3. Lubricate the mounting bracket pins with disc brake
Service Limit: 1.507” (38.28 mm) caliper lube, and install the rubber dust seal boots.
2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn
beyond service limit.

dust seals are fully seated. Install the brake pads.
Clean the disc and pads with brake parts cleaner or
denatured alcohol to remove any dirt, oil or grease.
MEASUREMENT
Caliper Piston O.D.:
Std: 1.500” (38.10 mm)
3. Inspect the brake disc and pads as outlined for brake

pad replacement in this chapter.
BRAKE SYSTEM
REAR CALIPER INSTALLATION

1. Install the rear caliper onto the mounting bolts.
Torque mounting bolts to specification.
TORQUE
Rear Caliper Mounting Bolts:
46 ft-lbs (62 Nm).
2. Install brake line banjo bolt. Torque banjo bolt to

specification.
TORQUE
Banjo Bolt:
15 ft-lbs (20 Nm)
3. Install the rear wheel and wheel nuts. Carefully lower

the vehicle.
4. Field test unit for proper braking action before putting
into service. Inspect for fluid leaks and firm brakes.
Make sure the brake is not dragging when pedal is
released. If the brake drags, re-check assembly and
installation. 9
NOTE
If new brake pads are installed, brake burnishing is
recommended (see “REAR BRAKE PADS - Brake
Burnishing Procedure”).
BRAKE SYSTEM
REAR BRAKE DISC

DISC RUNOUT BRAKE DISC INSPECTION
1. Mount a dial indicator and measure disc runout.
1. Check the surface condition of the brake discs.
Slowly rotate the disc and read total runout on the
dial indicator. Replace the disc if runout exceeds 2. Measure the thickness of the front and rear brake
specification. discs.
3. The disc (s) should be replaced if thickness is less
than the specified service limit
MEASUREMENT
Brake Disc Runout
Service Limit .010” (.254 mm) REF PART SERVICE LIMIT
q Front Disc See the
beginning of the
Brakes Chapter
w Rear Disc See the

beginning of the
Brakes Chapter
WARNING
Do not apply WD-40 or any petroleum product to brake
discs. These types of products are flammable and may
also reduce the friction between the brake pad and
caliper.
BRAKE SYSTEM
DISC REMOVAL / REPLACEMENT

1. Remove brake caliper (see “Brake Caliper Service”).
2. Remove cotter pin q, castle nut w and washers e.
3. Remove the wheel hub assembly from the vehicle
and remove the four bolts r retaining the disc to the
hub.
4. Clean the wheel hub mating surface and install new

disc on wheel hub.
5. Apply Loctite® 272 to new bolts, install and torque to
specification.
6. Install wheel hub assembly, washers, and castle nut.
Torque castle nut to specification and install a new
cotter pin.
TORQUE
Rear Brake Disc Mount Bolts:
27 ft-lbs (36 Nm)
Rear Hub Castle Nut:

110 ft-lbs (150 Nm)
Front Hub Castle Nut:

9
90 ft-lbs (122 Nm)
7. Install rear brake caliper (see “BRAKE CALIPER

SERVICE”). Follow the bleeding procedure outlined
earlier in this chapter.
8. Field test unit for proper braking action before putting
into service. Inspect for fluid leaks and firm brakes.
Make sure the brake is not dragging when pedal is
released. If the brake drags, re-check assembly and
installation.
BRAKE SYSTEM
PARKING BRAKE SYSTEM

PARKING BRAKE ASSEMBLY VIEW
NUMBER DESCRIPTION TORQUE (IF APPLICABLE)

q Bracket, Parking Brake Caliper —
w Mount, Parking Brake —
e Caliper Assembly, Parking Brake —
r Lever Assembly, Parking Brake —
t Brake System, Assembly —
y Shield, Master Cylinder —
u Screw, Cap —
i Boot, Park Brake —
o Cable Clamp —
a Routing Clip —
s Cable, Parking Brake —
d Screw - M8 x 1.25 x 55 (QTY.2) —
f Screw - 10-24 x 1 QTY.2) 35 in-lb (4 Nm)
g Bolt - M8 x 1.25 x 20 (QTY.2) 17 ft-lb (23 Nm)
BRAKE SYSTEM
NUMBER DESCRIPTION TORQUE (IF APPLICABLE)

h Bolt - M10 x 1.25 x 20 (QTY.8) 28 ft-lb (38 Nm)
j Bolt - M8 x 1.25 x 20 (QTY.4) 17 ft-lb (23 Nm)
k Nut - 5/16 – 18 (QTY.2) —
l Nut - M8 x 1.25 (QTY.2) 15 ft-lb (20 Nm)
1( Clevis Pin - 5/16 x 1 (QTY.1) —
2) Clip, Clevis Pin —
2! Clevis Pin - 1/4 x 3/4 (QTY.1) —
2@ Push Rivet (QTY.4) —
2# Clip, Silencer —
BRAKE SYSTEM
PARKING BRAKE CALIPER SERVICE

PARKING BRAKE CALIPER EXPLODED VIEW
PARKING BRAKE ADJUSTMENT 3. Disconnect cable from caliper lever arm by removing
See Maintenance Chapter pin retaining clip (A) and clevis pin (B).
CALIPER REMOVAL
1. Place vehicle on level ground and block the wheels.
2. Release the parking brake.
BRAKE SYSTEM
4. Loosen the two brake caliper mounting bolts (C). 2. Remove bolts, and pads with spacers and springs.
3. Disassemble shims, plate washer, lever arm, and

5. Remove parking brake caliper assembly. balls from bracket.
CALIPER DISASSEMBLY / INSPECTION

NOTE
The parking brake caliper is replaced as an assembly.
1. Remove two caliper assembly nuts (C).
4. Inspect three steel balls for any signs of pitting,

cracking, or flat spots.
9
5. Check ball seats in lever and stationary actuator. If
excessively worn, replace parts as needed.
BRAKE SYSTEM
6. Measure overall thickness of each brake pad and 2. Install lever arm with plate washer (do not install
compare to specifications. shims).
3. Install sleeves (do not install springs), rear pad, and

front pad.
4. Measure the gap between the friction material of the
pads and record.
NOTE
The front pad (as positioned in the caliper on the
vehicle) is thicker than the rear pad.
NEW BRAKE PAD INSTALLATION

1. Assemble the stationary actuator with bolts upright
as shown. Grease the tracks and install three balls.
BRAKE SYSTEM
5. Disassemble and add shims between plate washer 9. Ensure the assembly functions properly by actuating
and the rear brake pad as needed to close the gap to the lever before reinstallation. It should move freely
0.193”-0.203” (4.902 - 5.156 mm). and return to the upright position when released.
6. Install rear pad, spacers (if removed), springs, front

pad, and then loosely install the nuts. PARKING BRAKE CALIPER INSTALLATION
1. Install parking brake assembly on the mounting
bracket. Tighten two mounting bolts evenly to
specification.
7. Slide mounting bolt sleeves through the pads to

maintain alignment of parts. 2. Torque two bracket mounting bolts (if bracket was
removed) to specification.
8. Torque the assembly nuts to specification.
TORQUE
TORQUE
Caliper-to-Bracket Bolts:
Parking Brake Caliper - Assembly Bolts:
19 ft-lb (26 Nm)
35 ft-lb (47 Nm)
Caliper Bracket-to-Transaxle Case Bolts:
19 ft-lb (26 Nm)
3. Install the cable to lever arm with pin (pin is installed

from front to rear).
4. Install retainer clip in pin.
BRAKE SYSTEM
5. Test parking brake for proper function and adjust if

necessary.
BRAKE SYSTEM
PARKING BRAKE DISC SERVICE

DISC INSPECTION / REMOVAL
1. Measure parking brake disc thickness in multiple
spots using a micrometer. If the thickness of the disc
is less than specified at any point of the pad contact
surface, replace the rear propshaft / disc assembly.
2. Follow prop shaft removal procedure (See Final
Drive Chapter) to remove prop shaft / disc assembly.
BRAKE SYSTEM
TROUBLESHOOTING
BRAKES SQUEAL / POOR BRAKE
PERFORMANCE
• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Damaged break pad noise insulator
PEDAL VIBRATION
• Disc damaged
• Disc worn (runout or thickness variance exceeds
service limit)
CALIPER OVERHEATS (BRAKES DRAG)

• Compensating port plugged
• Pad clearance set incorrectly
• Parking brake lever incorrectly adjusted
• Brake pedal binding or unable to return fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes
BRAKES LOCK
• Alignment of caliper to disc
• Caliper pistons sticking
• Improper assembly of brake system components
BODY / FRAME
CHAPTER 10
BODY / FRAME
TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.2
CHASSIS / BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
FRAME ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.3
CREW FRAME ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.4
2015-2016 CAB FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.5
CREW CAB FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.6
DASH INSTRUMENTS / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.7
HOOD / DASH / FRONT FASCIA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.8
FLOOR / REAR FENDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10.9
SEAT MOUNTING / SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10
CREW FLOOR / REAR FENDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11
CREW SEAT MOUNTING / SEAT BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12
REAR CARGO BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
CARGO BOX - TAILGATE / BOX SUPPORT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
BOX REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
BOX INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
BODY COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
LOWER SEAT BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
FRONT BUMPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
FENDERS / FOOT PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
HOOD / DASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
FLOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
DECAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
10
BODY / FRAME
ITEM TORQUE VALUE SPECIAL TOOLS

Body T-40 Screws 8 ft-lbs (11 Nm) PART
TOOL DESCRIPTION
NUMBER
Bearing Carrier Fasteners 40 ft-lbs (54 Nm)
2870872 Shock Spanner Wrench
Ball Joint Fastener 30 ft-lbs (41 Nm)
2870623 Shock Spring Compressor Tool
Control Arm Fasteners 40 ft-lbs (54 Nm)
2876389 Multi-Function Pliers
2870871 Strut and Ball Joint Tool Set
2871573 Strut Spring Compressor (LH)
Seat Belt Mounting 40 ft-lbs (54 Nm)
Fasteners 2871574 Strut Spring Compressor (RH)
Shock Mounting Bolts Bosch Automotive Service Solutions: 1-800-345-2233

40 ft-lbs (54 Nm)
(rear) or http://polaris.service-solutions.com/
Steering Rack Mounting Included in this machine’s tool kit, the multi-function
16 ft-lbs (22 Nm) pliers is designed to remove the plastic push rivets used
Bolts
to fasten body components.
Steering Shaft to EPS 20 ft-lbs (27 Nm)
Steering Shaft to Steering 46–51 ft-lbs (62-69 Nm)
Rack
Strut Rod Retaining Nut
15 ft-lbs (21 Nm)
(Top)
Tie Rod End Jamb Nut 14 ft-lbs (19 Nm)
Tie Rod End Mounting 40 ft-lbs (54 Nm)
Nut
Wheel Lug Nuts 36 ft-lbs (49 Nm)
NOTE
Refer to exploded views throughout this chapter for
more torque specifications, component identification,
and location of components.
BODY / FRAME
CHASSIS / BODY
FRAME ASSEMBLY VIEW

q Main Frame
w Front Bumper
e Seat Base Frame
r Dash Support
t Left Floor Support
10
y Right Floor Support
u Skid Plate
i Bumper Screen
o Screws Torque to 22 ft-lbs (30 Nm)
a Screws Torque to 8 ft-lbs (11 Nm)
BODY / FRAME
CREW FRAME ASSEMBLY VIEW

q Rear Main Frame
w Front Main Frame
e Front Bumper
r Dash Support
t Left Floor Support
y Right Floor Support
u Front Skid Plate
i Rear Skid Plate
o Seat Base Frame
a Bumper Screen
s Screws Torque to 22 ft-lbs
d Screws Torque to 8 ft-lbs
f Screws Torque to 40 ft-lbs
BODY / FRAME
2015-2016 CAB FRAME

q Front Cab Frame
w Rear Cab Frame
e Screws Torque to 36 ft-lbs (49 Nm)
r Screws Torque to 36 ft-lbs (49 Nm)
t Screws Torque to 18 in-lbs (27 Nm)
10
y Screw Torque to 8 ft-lbs
BODY / FRAME
CREW CAB FRAME

q Front Cab Frame
w Middle Cab Frame
e Rear Cab Frame
r Cab Frame Brace
t Screws Torque to 36 ft-lbs (48 Nm)
y Screws Torque to 36 ft-lbs (48 Nm)
u Screws Torque to 36 ft-lbs (48 Nm)
i Nets - Door
BODY / FRAME
DASH INSTRUMENTS / CONTROLS

q Instrument Cluster
w Bezel
e Key Switch
r 12V Accessory Plug
t Turf Switch
y Dash Panel
10
BODY / FRAME
HOOD / DASH / FRONT FASCIA

q Hood
w Front Fascia
e Dash Panel
r Glove Box Lid
t Hood Strap
y Hood Hinge Pins
u Push Rivet
i Hood Latch
BODY / FRAME
FLOOR / REAR FENDERS

q Front Floor 10
w Main Floor
e Floor Cover
r Cup Holder
t Push Rivet
y Screws Torque to 5 ft-lbs (7 Nm)
BODY / FRAME
SEAT MOUNTING / SEAT BELTS

q Seat Back
w Seat Base
e LH Seat Belt Assm
r RH Seat Belt Assm
t Seat Base Frame
y Screw 24 in-lbs (3 Nm)
u Bolt 40 ft-lbs (54 Nm)
BODY / FRAME
CREW FLOOR / REAR FENDERS

q Front Floor 10
w Main Floor
e Front Seat Panel
r Rear Main Floor
t Storage Box
y Front Inner Fender
u Cup Holder
i Floor Cover
o Push Rivet
BODY / FRAME
CREW SEAT MOUNTING / SEAT BELTS

q Front Seat Base Frame
w Rear Seat Base Frame
e Seat Base
r Seat Back
t Screw 24 in-lbs (3 Nm)
y Bolt 40 ft-lbs (54 Nm)
BODY / FRAME
REAR CARGO BOX

CARGO BOX - TAILGATE / BOX SUPPORT
10
BODY / FRAME

q Cargo Box
w Box Frame
e Tailgate Inner Panel
r Tailgate Outer Panel
t Box Tilt Shock
y Box Tilt Latch
u Heat Shield
i Tailgate Tube
o Tailgate Mount Bracket
a Bushing
s Tailgate Latch
f Screw Torque to 5 ft-lbs (7 Nm)
BODY / FRAME
BOX REMOVAL BOX INSTALLATION

1. Remove the screw q that secures the hinge pin to 1. If the shock was replaced, install the lower portion of
the frame on both sides. the shock to the frame and secure it with the pin and
clip.
2. Place the cargo box onto the frame. Align the hinges
of the box with the bracket on the frame.
3. Install the box hinges on both sides.
4. Secure the box hinges with the hinge screws on both
sides.
5. With the hinges installed, attach the shock to the
cargo box by inserting the pin and clip.
6. Lower the box and secure the latch.
2. Lift the cargo box into the dump position.

3. Disconnect the rear wire harness attached to the tail
lights.
4. Remove the upper clip w and pin e attaching the
shock to the cargo box.
CAUTION
Safely support the box during the remainder of the
removal process. The box is not as stable with the 10
shock removed.
5. Remove the hinge pin from both sides.

6. With both hinge pins removed, remove the box from
the frame. Two people may be needed to remove the
box from the frame.
CAUTION
Use caution when removing the box. It is recommended
to have two people carefully remove the box from the
frame.
BODY / FRAME
BODY COMPONENT REMOVAL

LOWER SEAT BASE FENDERS / FOOT PADS
1. Lift up on the seat base to disengage the seat from 1. FRONT - Remove the lower T27 Torx-head screws
the rubber grommets q. retaining the foot pads.
2. Pull the seat base forward to disengage the rear tabs 2. Remove the two push rivets retaining the front fender
and remove the seat base from the vehicle. and remove the fender from the vehicle.
3. Repeat this procedure to remove the other front
FRONT BUMPER fender.
1. Unlatch the hood and disconnect the head lamp 4. REAR - Remove the lower T27 Torx-head screws
harnesses. Remove the two pivot screws retaining retaining the foot pads.
the hood and remove the hood from the bumper.
5. Remove the three T27 Torx-head screws retaining
2. Remove the three bolts from the lower portion of the the rear panel.
bumper.
6. Repeat this procedure to remove the other rear
fender.
3. Remove the two fasteners from each side of the

upper portion of the bumper.
4. Carefully remove the bumper from the vehicle.
BODY / FRAME
HOOD / DASH
1. Hood Removal - Unlatch the hood and disconnect
the head lamp harnesses. Remove the two clips and
pivot pins retaining the hood and remove the hood
from the bumper.
2. Dash Removal - Remove the three Torx-head
screws retaining the front of the dash to the frame.
3. Open the glove box and remove the Torx-head screw
from the dash.
4. Remove the Torx-head screw retaining the left

portion of the dash.
5. Remove the eight fasteners from each side of the
dash where it attaches to the front and rear fenders.
6. Remove the rubber boot from around shift lever.
7. Remove the five push rivets from under the dash
panel. Unhook all electrical components to allow the
panel to be completely removed.
8. Carefully remove the dash assembly from the
vehicle.
10
BODY / FRAME
FLOORS 5. Remove the Torx-head screws retaining the main

1. Remove the Foot pads. floor and remove the main floor from the vehicle.
2. Remove the rear fender push rivets. 6. Continue with ‘Hood / Dash Removal’ procedure.
3. Remove the seven Torx-head screws retaining the 7. Remove the accelerator and brake pedals for
center floor. adequate clearance to remove the front floor section.
4. Remove the Torx-head screws retaining the front

floor cover.
BODY / FRAME
DECAL REPLACEMENT
WARNING
The following procedure involves the use of an open
flame. Perform this procedure in a well ventilated area,
away from gasoline or other flammable materials. Be
sure the area to be flame treated is clean and free of
gasoline or flammable residue.
WARNING
Do not flame treat components that are installed on the
vehicle. Remove the component from the vehicle
before flame treating.
The side panels, front and rear fender cabs are plastic
polyethylene material. Therefore, they must be “flame
treated” prior to installing a decal to ensure good
adhesion. A bonus of the flame treating procedure is it
can be used to reduce or eliminate the whitish stress
marks that are sometimes left after a fender or cab is
bent, flexed, or damaged.
To flame treat the decal area:
1. Pass the flame of a propane torch back and forth
quickly over the area where the decal is to be applied
until the surface appears slightly glossy. This should
occur after just a few seconds of flame treating. Do
not hold the torch too close to the surface (2-3 inches
from the flame tip is recommended). Keep the torch
moving to prevent damage.
2. Apply the decal on one edge first. Slowly lay down
remainder of the decal while rubbing lightly over the
decal surface to eliminate any air bubbles during the
application.
10
BODY / FRAME
NOTES
ELECTRICAL
CHAPTER 11
ELECTRICAL
GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
ELECTRICAL SERVICE NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
BATTERY CONDUCTANCE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.3
COMPONENTS UNDER HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.4
SWITCHES / CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
IGNITION / HEADLIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
AWD / 2WD / TURF SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.5
DIFFERENTIAL SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
REAR DIFFERENTIAL SOLENOID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
BRAKE PRESSURE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.6
ALL WHEEL DRIVE (AWD) COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
DIAGNOSING SYSTEM FAILURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.7
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
SPEED SENSOR LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
SPEED SENSOR TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.8
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.9
RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.10
INFORMATION DISPLAY AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11.11
DIAGNOSTIC MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.13
INSTRUMENT CLUSTER PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14
INSTRUMENT CLUSTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14
INSTRUMENT CLUSTER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.14
HEADLIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
HEADLIGHT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.16
HEADLIGHT BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.17
HEADLIGHT HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.17
HEADLIGHT HOUSING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.17
TAIL LIGHT / BRAKE LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.18
LED LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.18
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.19
11
FAN CONTROL CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.19
FAN CONTROL CIRCUIT BYPASS TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.19
IGNITION COIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.20
OPERATION OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.20
IGNITION COIL TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.20
PRIMARY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.20
SECONDARY TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.20
IGNITION COIL AND HT LEAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.21
ELECTRICAL
RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.22
FUSES / CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.24
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.24
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25
CURRENT DRAW - KEY OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25
CHARGING SYSTEM “BREAK EVEN” TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25
CHARGING SYSTEM ALTERNATOR TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.25
CHARGING SYSTEM TESTING FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.27
BATTERY SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.28
BATTERY TERMINALS / BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.28
BATTERY TERMINAL BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.28
BATTERY ACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.28
BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.29
BATTERY REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.30
CONVENTIONAL BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.30
OCV - OPEN CIRCUIT VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.30
VOLTAGE DROP TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.30
SPECIFIC GRAVITY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.31
LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.31
CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.31
OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.31
STARTER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.32
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.32
STARTER MOTOR DOES NOT RUN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.32
STARTER MOTOR TURNS OVER SLOWLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.32
STARTER MOTOR TURNS - ENGINE DOES NOT ROTATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.32
STARTER DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.32
STARTER SOLENOID BENCH TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.33
STARTER SOLENOID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.34
STARTING SYSTEM TESTING FLOW CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.35
ELECTRICAL
GENERAL INFORMATION
SPECIAL TOOLS BATTERY CONDUCTANCE ANALYZER
PART Conductance describes the ability of a battery to conduct
TOOL DESCRIPTION current. A conductance tester functions by sending a low
NUMBER
frequency AC signal through the battery and a portion of
PV-43568 Fluke™ 77 Digital Multimeter the current response is captured, from this output a
PV-43526 Connector Test Kit conductance measurement is calculated. Conductance
2870630 Timing Light testing is more accurate than voltage, specific gravity, or
2870836 Battery Hydrometer load testing.
2460761 Hall Sensor Probe Harness Authorized Polaris dealers/distributors are required to
2871745 Static Timing Light Harness use the conductance analyzer when testing 12V Polaris
batteries.
PU-47063 Digital Wrench™ Diagnostic Software
PU-47471 Digital Wrench™ SmartLink Module Kit
PU-50296 Battery Conductance Analyzer
ELECTRICAL SERVICE NOTES

Keep the following notes in mind when diagnosing an
electrical problem:
• Refer to wiring diagram for stator and electrical
component resistance specifications.
• When measuring resistance of a component that has a
resistance value under 10 Ohms, remember to
subtract meter lead resistance from the reading.
Connect the leads together and record the resistance.
The resistance of the component is equal to tested
value minus the lead resistance.
• Become familiar with the operation of your meter. Be
sure leads are in the proper jack for the test being
performed (i.e. 10A jack for current readings). Refer to Polaris MDX-610P
the Owner’s Manual included with your meter for more Bosch PN: PU-50296
information.
• Voltage, amperage, and resistance values included in
this manual are obtained with a Fluke™ 77 Digital
Multimeter. This meter is used when diagnosing
electrical problems. Readings obtained with other
meters may differ.
Fluke™ 77 Digital Multimeter:
PV-43568
• Pay attention to the prefix on the multimeter reading

(K, M, etc.) and the position of the decimal point.
• For resistance readings, isolate the component to be 11
tested. Disconnect it from the wiring harness or power
supply.
ELECTRICAL
COMPONENTS UNDER HOOD

The following components can be accessed under the
hood.
• Voltage Regulator
• Terminal Block
• Digital Wrench Diagnostic Connector
• AWD/2WD/TURF Switch
• 12 VDC Accessory Power Point
• Ignition Switch
• Instrument Cluster
• Cooling Fan
• TRS Connector
• Brake Switch
• Headlights
ELECTRICAL
SWITCHES / CONTROLS
IGNITION / HEADLIGHT SWITCH AWD / 2WD / TURF SWITCH
1. Open the hood (see Chapter 5). 1. Remove the dash panel from the dash (see Chapter
5).
2. Disconnect the ignition switch harness, by
depressing the connector lock and pulling on the 2. Disconnect the switch harness (Gray, Orange/White,
connector. Do not pull on the wiring. Brown, White/Green), by depressing the connector
lock and pulling on the connector. Do not pull on the
3. Inspect the switch connections and test the switch
wiring.
for continuity.
• Turn the ignition key to ON LIGHTS. There should be 3. Inspect the switch connections and test the switch
continuity between switch pins C and D; A, E and F. for continuity.
• Turn the ignition key to ON. There should be continuity • When the switch is in position #1 (AWD), there should
between switch pins C and D; E and F. be continuity between terminals 2 (Orange/White) and
• Turn the ignition key to START. There should be 3 (Gray).
continuity between switch pins A and B; C and D; E • When the switch is in position #3 (TURF), there should
and F. be continuity between terminals 1 (White/Green) and 2
(Orange/White).
11
ELECTRICAL
DIFFERENTIAL SOLENOID • Remove solenoid from rear differential and ensure the
The differential solenoid q is located on the right side of solenoid plunger is actuating.
the transmission. The solenoid actuates an engagement
CAUTION
dog, which locks and unlocks the rear differential. Refer
to Chapter 8 for more information on the rear differential Do not power the solenoid with 12 Volts for more than 1
mechanical operation. second, or damage may occur to solenoid.
BRAKE PRESSURE SWITCH

The brake pressure switch q is located on the rear brake
line outlet on the master cylinder.
REAR DIFFERENTIAL SOLENOID OPERATION

The Rear Diff Solenoid Relay is located on the frame
under the rear cargo box.
When the switch is pushed to activate “TURF” mode,
key-on accessory battery voltage is sent from the AWD /
2WD / TURF Switch to the ECU.
Depending on engine speed and gear position criteria, TORQUE
the ECU energizes the Rear Diff Solenoid Relay allowing Master Cylinder Brake Pressure Switch / Banjo Bolt:
it to enable the differential solenoid. 180 in-lbs +/- 10 in-lbs
NOTE
Always replace brake system seals if fastener is
loosened or removed.
1. Disconnect the wire harness from the brake switch.

2. Connect an ohmmeter across switch contacts.
Reading should be infinite (OL).
3. Apply foot brake and check for continuity between
switch contacts. If there is no continuity or greater
than .5 ohms resistance when the brake is applied
with slight pressure, first clean the switch contacts
and re-test. Replace switch if necessary.
If the rear differential fails to switch from operational

modes:
• Check the solenoid and relay connectors. Look for
loose wires or bad connections.
• Check for power from the relay connector, to ensure
the solenoid has power to be activated. Check for
power at the ECU and Rear Differential Solenoid
Relay.
• Check the switch wires for loose connections.
ELECTRICAL
ALL WHEEL DRIVE (AWD) COIL

OPERATION OVERVIEW
• When the AWD switch is “ON”, 12 VDC power is
present at the hub coil on the Red/Green wire.
• If the criteria is met, the ECU provides a ground path
on the Brown/White wire.
• The AWD system must be grounded to operate.
DIAGNOSING SYSTEM FAILURES

• Verify the AWD switch is functional and that a
minimum of 11 volts is present at the hub coil on the
Gray wire.
• Verify the AWD hub coil is functional. Test the AWD
hub coil using an ohm meter. See specifications below:
AWD Hub Coil Resistance:

24 Ohms ± 5%
• Verify the wiring harness, wiring, connectors,

connector pins and grounds are undamaged, clean
and connected properly.
• Verify continuity of wire connections with a volt/ohm
meter.
11
ELECTRICAL
VEHICLE SPEED SENSOR

SPEED SENSOR LOCATION 4. Be sure connections are good and 9V battery is in
The speed sensor q is located on the right side of the good condition. If the light flashes, the sensor is
transmission case and can be accessed from behind the good.
right rear wheel.
SPEED SENSOR TESTING

Special Tools Required:
Static Timing Light Harness (PN 2871745)
Hall Sensor Probe Harness (PN 2460761)
1. Disconnect the 3 wire harness from the speed
sensor and remove the sensor from the
transmission.
2. Connect the wires from the Static Timing Light
Harness to the sensor 3 pin connector using the Hall
Sensor Probe Harness (PN 2460761).
3. Pass a screwdriver back and forth in front of the
sensor tip.
ELECTRICAL
INSTRUMENT CLUSTER
OVERVIEW
The instrument cluster displays critical vehicle information to the user. Reference the following page for display
functions and descriptions.
11
NOTE
Some features are not applicable to all models.
The use of a high pressure washer may damage the instrument cluster. Wash the vehicle by hand or with a garden
hose using mild soap. Certain products, including insect repellents and chemicals, will damage the instrument cluster
lens. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately
clean off any gasoline that splashes on the instrument cluster.
ELECTRICAL
RIDER INFORMATION DISPLAY 13. Gear Position Indicator - Displays gear selector
The rider information display is located in the instrument position.
cluster. All segments will light up for 1 second at start-up. H = High
L = Low
NOTE
N = Neutral
If the instrument cluster fails to illuminate, a battery R = Reverse
over-voltage may have occurred and the instrument
cluster may have shut off to protect the electronic P = Park
speedometer. – = Gear Signal Error (shifter stuck between gears)
14. Power Steering System MIL - LED icon illuminates
1. Vehicle Speed Display - Analog display of vehicle when a fault has occurred with the power steering
speed in MPH or km/h. system. This indicator illuminates when the key is
2. Information Display Area - Odometer / Trip Meter turned to the ON position and goes off when the
/ Tachometer / Engine Temperature / Engine engine is started (EPS Option Only).
Hours / Service Info / Clock - LCD display of the 15. Turn Signal / Hazard Lamp Indicator - LED icon
service hour interval, total vehicle miles or km., total illuminates whenever the LH, RH or hazard lamps
engine hours, a trip meter, engine RPM and engine are activated (INT’L Models Only).
temperature.
16. Helmet / Seat Belt Indicator - LED icon illuminates
3. MPH / KM/H Display - MPH is displayed when the for several seconds when the key is turned to the ON
instrument cluster is in the Standard mode. KM/H is position. The lamp is a reminder to the operator to
displayed when the instrument cluster is in the Metric ensure all riders are wearing helmets and seat belts
mode. before operating the vehicle.
4. High Beam Indicator LED icon illuminates
whenever the Headlamp switch is in the high beam
position.
5. Fuel Level Indicator - LCD bar graph indicating
current fuel level. All segments will flash when the
last segment is cleared indicating a low fuel warning.
6. Clock - Displays current time in either 12-hour or 24-
hour formats.
7. Engine Temperature Indicator - LED icon
illuminates when the ECM determines the engine is
overheating. The indicators will initially flash to
indicate the engine is overheating. The indicators will
stay lit and not flash if a severe overheating condition
exists.
8. Service Interval Indicator - Preset at the factory
and adjustable by the user, a flashing wrench symbol
alerts the operator that the preset service interval
has been reached and maintenance should be
performed. The wrench icon will flash for 10 seconds
upon start-up once it reaches 0.
9. Check Engine MIL - Illuminated when the ECM has
detected a Diagnostic Trouble Code in the engine
management system.
10. AWD Indicator - Illuminated when the AWD / TURF
switch is in the AWD position.
11. TURF Indicator - Illuminated when the AWD / TURF
switch is in the TURF position.
12. Neutral Gear Indicator - LED icon illuminates when
gear selector is in the neutral (N) position.
ELECTRICAL
INFORMATION DISPLAY AREA 2. To reset to 0, push and hold the MODE button until
The LCD portion of the instrument cluster is the the distance display changes to 0.
information display area. Information displayed in this Tachometer (RPM)
area includes: odometer, trip meter, engine RPM, engine
hours, service interval, clock, engine Diagnostic Trouble
Codes (DTCs) and power steering DTCs.
Odometer
Engine RPM can be displayed digitally.

Engine Temperature
The odometer records and displays the total distance

traveled by the vehicle. The odometer can not be reset.
Trip Meter
Engine temperature can be displayed in Â ° F or Â °

C. Refer to “Units of Measurement” to change the
format.
Engine Hours
The trip meter records the miles traveled by the vehicle

on each trip. To reset the trip meter:
1. Toggle the MODE button to TRIP 1.
11
Engine hours are logged anytime the engine is

running. Total hours can not be reset.
ELECTRICAL
Programmed Service Interval 9. With the segment flashing, tap the MODE button to
advance to the desired setting.
10. Press and hold the MODE button until the next
segment flashes. Release the button.
11. Repeat steps 3-4 twice to set the 10 minute and 1
minute segments. After completing the 1-minute
segment, step 4 will save the new settings and exit
the clock mode.
Units of Measurement
STANDARD METRIC
DISPLAY DISPLAY
Kilometers (KM/
Distance Miles (MPH)
H)
The initial factory service interval setting is 50 hours.
Each time the engine is started, the engine hours are Time 12-Hour Clock 24-Hour Clock
subtracted from the service interval hours. When the Tempera-
service interval reaches 0, the LCD wrench icon will Fahrenheit Celsius
ture
flash for approximately 10 seconds each time the
engine is started. To change between Standard and Metric units of
To change the hour setting or reset the function, measurement, follow these steps:
follow these steps:
12. Turn the key to the OFF position.
3. Toggle the MODE button until the wrench icon is
displayed in the information area. 13. Press and hold the MODE button while turning the
key to the ON position.
4. Press and hold the MODE button until the
information display area begins to flash. 14. When the display flashes the distance setting, tap
the MODE button to advance to the desired setting.
5. Toggle the MODE button to increase the service
interval hours in 5 hour increments to a maximum of
100 hours.
6. To turn off the service interval function, toggle the
MODE button until “OFF” is displayed.
Clock
The clock displays the time in a 12-hour or 24-hour

format. Refer to “Units of Measurement” to change
the format (Standard 12-hour / Metric-24 hour). To
set the clock, follow these steps:
7. Toggle the MODE button until the odometer is
displayed.
8. Press and hold the MODE button until the hour
segment flashes. Release the button.
ELECTRICAL
15. Press and hold the MODE button to save the setting will remain stored in the gauge (even if MIL turns off) until
and advance to the next display option. the key is turned off.
16. Repeat the procedure to change remaining display 1. If the trouble code (s) are not displayed, use the
settings. MODE button to toggle until “CK ENG” displays on
Under / Over Voltage the information display area.
This warning usually indicates that the vehicle is
operating at an RPM too low to keep the battery
charged. It may also occur when the engine is at idle
and a high electrical load is applied (lights, cooling
fan or other accessories).
If battery voltage drops below 11 volts, a warning
screen will display “Lo” and provide the present
battery voltage. If voltage drops below 8.5 volts, LCD
backlighting and icons will turn off.
2. Press and hold the MODE button to enter the

diagnostics code menu.
3. A set of three numbers will appear in the information
area.
• The first number (located far left) can range from 0 to
9. This number represents the total number of trouble
codes present (example: 2 means there are 3 codes
present).
• The second number (located top right) can be 2 to 6
If battery voltage rises above 15 volts, a warning digits in length. This number equates to the suspected
screen will display “OV” and provide the present area of fault (SPN).
battery voltage. If voltage rises above 16.5 volts, • The third number (located bottom right) can be 1 to 2
LCD backlighting and icons will turn off. digits in length. This number equates to the fault mode
(FMI).
11
DIAGNOSTIC MODE
The diagnostic mode is accessible only when the check
engine MIL has been activated.
Use the following procedure to display diagnostic trouble 4. Use the trouble code reference table in the EFI
codes that were activated during current ignition cycle Chapter for a description of each code.
causing the MIL to illuminate. Diagnostic trouble codes 5. If more than one code exists, press the MODE button
to advance to the next trouble code.
ELECTRICAL
6. To exit the diagnostic mode, press and hold the 3. Push the instrument cluster out from the back side of
MODE button or turn the ignition key OFF once the the dash panel, while securely holding the panel and
codes are recorded. rubber mount.
NOTE
If there is a diagnostic problem with the power steering
system, the power steering MIL will illuminate and blink
in place of the check engine MIL.
INSTRUMENT CLUSTER PINOUTS
NOTE
Do not remove the rubber mount from the dash panel.
Only remove the rubber mount if necessary.
FUNCTION PIN INSTRUMENT CLUSTER INSTALLATION

CAN High 1 1. Spray a soap and water mixture onto the outer
surface area of the instrument cluster. This will help
CAN Low 2 the instrument cluster slide into the rubber mount
more easily.
Switched Power (Vdc) 3
Constant Power (Vdc) 4
Ground 5
High Beam 8
Fuel Level Sensor 11
INSTRUMENT CLUSTER REMOVAL

NOTE
Do not allow alcohol or petroleum products to come in
contact with the instrument cluster lens.
2. Be sure the rubber mount inside the dash panel is
1. Remove seat, disconnect battery and open hood to fully installed and that the indexing key on the rubber
gain access to back of instrument cluster. mount is lined up with the keyway in the dash panel.
2. Disconnect the wire connectors from the back side of 3. Hold the dash panel securely and insert the
the instrument cluster. instrument cluster into the dash panel. Twist the
instrument cluster gently in a clockwise motion to
properly seat the instrument cluster. Apply pressure
on the bezel while pressing down on the instrument
cluster.
ELECTRICAL
11
ELECTRICAL
HEADLIGHTS
HEADLIGHT ADJUSTMENT 6. Once the beam is set to the position, tighten the
The headlights are adjustable. adjustment screw. Repeat the procedure to adjust
the other headlight.
1. Place the vehicle on a level surface with the
headlight approximately 25 ft. (7.6 m) (Item 1) from a WARNING
wall.
Due to the nature of light utility vehicles and where they
are operated, headlight lenses become dirty. Frequent
washing is necessary to maintain lighting quality. Riding
with poor lighting can result in severe injury or death.
2. Measure the distance from the floor to the center of

the headlight (X1) and make a mark on the wall at the
same height (X2).
3. With the machine in Park and wheels chocked, start
the engine and turn the headlight switch on.
4. The most intense part of the headlight beam should
be aimed 8 in. (20 cm) (item 2) below the mark
placed on the wall in Step 2.
NOTE
Rider weight must be included in the seat while
performing this procedure.
5. Locate the T25 Torx-head adjustment screw through

the wheel well (see illustration). Adjust the beam to
the desired position by loosening the adjustment
screw and moving the lamp to the appropriate
height.
ELECTRICAL
HEADLIGHT BULB REPLACEMENT HEADLIGHT HOUSING REMOVAL

1. Open the hood. 1. Open the hood.
2. Locate the bulb on the back side of headlight q. 2. Remove the bulb from the headlight housing (see
“Headlight Bulb Replacement”).
3. Turn the bulb counterclockwise to remove it.
3. Remove the O-rings q from each side of the
headlight housing. Remove the adjustment screw w
and pull the headlight from the brackets.
4. Unplug the headlight bulb from the wiring harness.

Be sure to pull on the connector, not on the wiring.
HEADLIGHT HOUSING INSTALLATION

1. Install the headlight housing by pressing the
headlight tabs back into the brackets.
2. Secure the headlight housing with the rubber O-rings
on each side q. Install the adjustment screw w.
NOTE
Be sure to twist the O-rings upon installation as shown
below.
5. Install the wire harness into the new headlight bulb.

6. Install the bulb into the housing and rotate it
clockwise 90° to lock it in place.
NOTE
Make sure the tab on the bulb locates properly in the
housing.
11
3. Reinstall the bulb into the housing and rotate it

clockwise 90° to lock it in place.
4. Close the hood and adjust headlights using the
“Headlight Adjustment” procedure.
ELECTRICAL
TAIL LIGHT / BRAKE LIGHT

LED LAMP REPLACEMENT
1. From the rear of the LED lamp, remove the (2) T20
Torx-head screws q retaining the lamp assembly.
2. Remove the lamp from the cargo box and disconnect

the tail light / brake light wire harness.
NOTE
Before replacing the LED lamp assembly, use a digital
multi-meter to test the harness to ensure the lamp is
receiving 12-14 DC volts and that a ground path is
present. Lamps can be bench tested by applying 12-14
volts directly, as the LED tail/brake lamp units are
internally regulated.
3. If the LED lamp does not function with power and

ground applied to the lamp directly, replace the lamp
assembly. Apply dielectric grease (PN 2871329) to
the new lamp connector terminals.
4. Reinstall the assembly by reversing this procedure.
5. Test after installation to verify proper function of tail,
brake, and turn signal lamps.
ELECTRICAL
COOLING SYSTEM
FAN CONTROL CIRCUIT OPERATION
Power is supplied to the fan via the Orange/Black wire
when the relay is energized. The brown wire provides a
ground path for the fan motor. Refer to “RELAYS” later in
this chapter for more information on fan functions.
CAUTION
Keep hands away from fan blades during operation.
Serious personal injury could result.
NOTE
The fan may not function or operation may be delayed if
coolant level is low or if air is trapped in the cooling
system. Be sure cooling system is full and purged of air.
Refer to Chapter 2 “Maintenance” for cooling system
information.
FAN CONTROL CIRCUIT BYPASS TEST

1. Disconnect harness from the engine coolant
temperature sensor located in the cylinder head of
the engine.
2. With the vehicle in park, turn the key on. After a few
seconds, you should hear the cooling fan turn on and
remain running.
3. If the fan does not run or runs slowly, check the fan
motor wiring, wire connections, ground path, 12V
power input, and fan motor condition. Repair or
replace as necessary. If the fan runs while the engine
is running with the sensor harness disconnected, but
will not turn on when the engine is hot, verify the
coolant level is correct and check the coolant
temperature sensor and connector terminals.
11
ELECTRICAL
IGNITION COIL
OPERATION OVERVIEW PRIMARY TEST
The ignition coil q is used to provide high voltage to fire
the spark plug. When the ignition key is on, DC voltage is
present in primary side of the ignition coil windings.
During engine rotation, an AC pulse is created within the
crankshaft position sensor for each passing tooth on the
flywheel. The two-tooth gap creates an “interrupt” input
signal, corresponding to specific crankshaft position. This
signal serves as a reference for the control of ignition
timing. The ECU then calculates the time interval
between the consecutive pulses, and determines when
to trigger the voltage spike that induces the voltage from
the primary to the secondary coil windings to fire the
spark plug.
SECONDARY TESTS
IGNITION COIL TESTS

The ignition coil can be tested by using an Ohm meter.
Use the following specification table and illustrations to
test the ignition coil.
Ignition Coil Resistance Readings

TEST PIN CONNECTION RESISTANCE
Between Battery (+) &
Primary 0.5 Ω ± 10%
Coil (-)
Between Coil (-) and
Primary
(+) at the Coil 0.5 Ω
Test
Connection
Secondary Between High Tension
Lead Caps 7.0 k Ω ± 5%
Test
ELECTRICAL
IGNITION COIL AND HT LEAD

REPLACEMENT
1. Remove the drivers seat and disconnect the (-)
negative battery cable.
2. Disconnect harness connection to the ignition coil.
3. Remove high tension lead cap q from the spark
plug.
4. Remove fasteners w retaining the ignition coil and

remove coil assembly from the vehicle.
5. Install new ignition coil assembly and tighten

NOTE
Be sure to reinstall the coil mounting spacers upon
assembly (if equipped).
11
TORQUE
Ignition Coil Retaining Bolt:
75 in-lbs (8.5 Nm)
6. Connect harness connection to the ignition coil.

7. Reconnect battery cable and install the drivers seat.
ELECTRICAL
RELAYS
OPERATION • EFI Relay, controlled by the ECM, supplies power to
The relays assist with fan, ignition coil, fuel pump, brake EFI components and sensors.
light, EFI, headlight, EPS, and rear differential operation. EFI Relay
• Fan Relay, controlled by the ECM and engine coolant
temperature sensor, operates the fan motor. FUSE
BOX WIRE
Fan Relay PIN COLOR OPERATION
17 Red Relay coil 12v from
FUSE Unswitched Fused EFI
BOX WIRE Splice
PIN COLOR OPERATION
18 Red High side 12v from
9 Red / Dark Relay coil 12v from EFI
Unswitched Fused EFI
Blue Splice
Splice
10 Orange / High side 12v from 15A
21 Red / Dark 12v output to EFI Splice #1
Black circuit breaker
Blue
13 Orange / 12v output to fan motor
22 Dark Green ECU controlled ground
Black
/ Yellow
14 Orange / ECU controlled ground
Black • Headlight Relay, controlled by the ignition switch,
supplies power to the headlights.
• Fuel Pump Relay, controlled by the ECM and key
switch, powers the fuel pump. Headlight Relay
Fuel Pump Relay FUSE
BOX WIRE
FUSE PIN COLOR OPERATION
BOX WIRE
1 Red / Relay coil 12v from Lights
PIN COLOR OPERATION
Yellow splice
25 Red / Dark Relay coil 12v from EFI
Blue Splice 2 Red / High side 12v from Lights
Yellow splice
26 Orange High side 12v from Fuel
Pump fuse 5 Dark Green 12v output to Headlight Low
Beam splice
29 Red / Blue Ground, Chassis Rear #1
6 White / Red Ignition switch controlled
30 Dark Green ECU controlled ground ground
/ Yellow
• EPS Relay (if equipped), controlled by the ignition
• Chassis Relay, controlled by the key switch, supplies
switch, provides power to the EPS unit.
B+ to the chassis circuits.
Chassis Relay EPS Relay
FUSE
FUSE
BOX WIRE
BOX WIRE
PIN COLOR OPERATION
PIN COLOR OPERATION
3 Orange Relay coil 12v from R/S B+
33 Red / Blue Relay coil 12v from EFI
Splice #2
Splice
4 Red High side 12v from EPS fuse
34 Red High side 12v from Start
Solenoid 7 Orange 12v output to EPS unit
37 Red 12v output to Splice, Chassis 8 Brown Chassis ground #2
38 Gray ECU controlled ground
ELECTRICAL
• Rear Differential Solenoid Relay, controlled by the

AWD/2WD/TURF switch and ECM, operates the
differential solenoid to unlock the rear end.
11
ELECTRICAL
FUSES / CIRCUIT BREAKER

OPERATION
The fuses, located in the relay/fuse box under driver’s seat base, provide current protection for components such as
the EFI system, main harness, lights and accessories.
FUSE SIZE FEATURE SUPPORTED

5A Brake Light
10 A Drive System, Fuel Pump
20 A EFI, Power Steering (if equipped), Lights, Accessories
20 A Circuit Breaker Fan
ELECTRICAL
CHARGING SYSTEM
CURRENT DRAW - KEY OFF WARNING
CAUTION Never start the engine with an ammeter connected in
series. Damage to the meter or meter fuse will result.
Do not connect or disconnect the battery cable or
ammeter with the engine running. Damage will occur to Do not run test for extended period of time.
electrical components. Do not run test with high amperage accessories.
Connect an ammeter in series with the negative battery 1. Turn key on and push the Mode button until the
cable. Check for current draw with the key off. If the draw instrument cluster is displaying RPM.
is excessive, loads should be disconnected from the 2. Using an inductive amperage metering device, (set
system one by one until the draw is eliminated. Check to DC amps) connect to the negative battery cable.
component wiring as well as the component for partial
shorts to ground to eliminate the draw. 3. With engine off and the key switch “ON/Lights”
position, the ammeter should read negative amps
(battery discharge). Reverse meter lead if a positive
reading is indicated.
4. Shift transmission into park and start the engine.
With the engine running at idle, observe meter
readings.
5. Increase engine RPM while observing ammeter and
tachometer.
6. Note RPM at which the battery starts to charge
(ammeter indication is positive).
7. With lights and other electrical loads off, the “break
even” point should occur at approximately 1500 RPM
or lower.
8. With the engine running, turn the lights on and apply
the brake to keep brake light on.
9. Repeat test, observing ammeter and tachometer.
With lights on, charging should occur at or below
Current Draw - Key Off: 2000 RPM.
Maximum of .01 DCA (10 mA)
CHARGING SYSTEM ALTERNATOR TESTS
Three tests can be performed using a multimeter to
CHARGING SYSTEM “BREAK EVEN” TEST determine the condition of the stator (alternator).
CAUTION
Do not allow the battery cables to become
disconnected with the engine running. Follow the steps
below as outlined to reduce the chance of damage to
electrical components.
The “break even” point of the charging system is the 11

point at which the alternator overcomes all system loads
(lights, etc.) and begins to charge the battery. Depending
on battery condition and system load, the break even
point may vary slightly. The battery should be fully
charged before performing this test.
ELECTRICAL
TEST 1: Resistance Value of Each Stator Leg 5. Set the selector dial to measure AC Voltage.
1. Measure the resistance value of each of the three 6. Start the engine and let it idle.
stator legs: Y1 to Y2, Y1 to Y3, and Y2 to Y3.
7. While holding the engine at a specified RPM,
2. Each test should measure: 0.15 Ω ± 20% separately measure the voltage across each ‘leg’ of
the stator by connecting the meter leads to the wires
CONNECT leading from the alternator (Y1 to Y2, Y1 to Y3, Y2 to
OHMS
TEST METER Y3).
READING
LEADS TO:
8. Refer to the following table for approximate AC
Battery Charge Voltage readings according to RPM. Test each leg at
Y1 to Y2 Less than 1 Ω
Coil the specified RPM in the table.
Battery Charge
Y1 to Y3 Less than 1 Ω
Coil 9. Example: The alternator current output reading
Battery Charge should be approximately 18 VAC at 1300 RPM
Y2 to Y3 Less than 1 Ω between each ‘leg’.
Coil
NOTE
NOTE If one or more of the stator leg output AC voltage varies
If there are any significant variations in ohm readings significantly from the specified value, the stator may
between the three legs it is an indication that one of the need to be replaced.
three stator legs maybe weak or failed.
AC VOLTAGE (VAC)
TEST 2: Resistance Value of Each Stator Leg to RPM READING
READING
Ground
1300 21 VAC ± 25 %
3. Measure the resistance value of each of the stator
legs to ground: Y1 to Ground, Y2 to Ground, Y3 to 3000 49 VAC ± 25 %
Ground.
5000 80 VAC ± 25 %
4. Each test should measure: Open Line (OL)
CONNECT
OHMS
TEST METER
READING
LEADS TO:
Battery Charge Y1, Y2, or Y3 Open Line
Coil to Ground (Infinity)
NOTE
Any measurement other than Infinity (open) will indicate
a failed or shorted stator leg.
TEST 3: Measure AC Voltage Output of Each

Stator Leg at Charging RPM
ELECTRICAL
CHARGING SYSTEM TESTING FLOW

CHART
Whenever charging system problems are suspected, proceed with the following system check after verifying that all
wires are in good condition, connected and not exposed or pinched.
11
ELECTRICAL
BATTERY SERVICE
BATTERY TERMINALS / BOLTS BATTERY ACTIVATION
Use Polaris corrosion resistant Nyogel™ grease (PN
2871329) on battery terminal bolts. WARNING
Battery electrolyte is poisonous. It contains sulfuric
acid. Serious burns can result from contact with skin,
eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow
with milk of magnesia, beaten egg, or vegetable oil. Call
physician immediately.
Eyes: Flush with water for 15 minutes and get prompt
medical attention.
Batteries produce explosive gases. Keep sparks, flame,
cigarettes etc. away.
Ventilate when charging or using in an enclosed space.
Always shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
BATTERY TERMINAL BLOCK WARNING

The terminal block q is located under the hood next to The gases given off by a battery are explosive. Any
the battery and fuse box. The terminal block provides spark or open flame near a battery can cause an
easy hookup for accessories. explosion which will spray battery acid on anyone close
to it. Should there be contact with battery acid, wash the
affected area with large quantities of cool water and
seek immediate medical attention.
To ensure maximum service life and performance from a

new battery, perform the following steps.
NOTE
Do not service the battery unless it will be put into
regular service within 30 days. After initial service, add
only distilled water to the battery. Never add electrolyte
after a battery has been in service.
NOTE
New Battery: Battery must be fully charged before use
TORQUE or battery life will be significantly reduced 10-30% of the
battery’s full potential.
Terminal Block Nuts:
20-25 in-lbs (2.3-2.8 Nm)
To activate a new battery:
1. Remove all the filling plugs.
WARNING 2. Remove the sealing tube (red cap) from vent fitting.
CALIFORNIA PROPOSITION 65 WARNING:
3. Place battery on a level surface. Fill battery with
Batteries, battery posts, terminals and related electrolyte to upper level marks on the battery case.
accessories contain lead and lead compounds, and
other chemicals known to the State of California to NOTE
cause cancer and birth defects or other reproductive
harm. WASH HANDS AFTER HANDLING. Never activate a battery on the vehicle. Electrolyte
spillage can cause damage.
ELECTRICAL
4. Set battery aside to allow for acid absorption and 2. Make sure the battery top is clean and dry. A dirty
stabilization for 30 minutes. battery actually discharges across the grime on top
of the case. Use a soft brush and a baking soda
5. Add electrolyte to bring the level back to the upper
solution. Make sure plugs are finger tight so cleaning
level mark on the battery case.
solution doesn’t get into the cells and neutralize the
6. Charge battery for 3 - 5 hours at 1/10 of its amp/hour acid.
rating. Examples: 1/10 of 9 amp battery = .9 amp; 1/
10 of 14 amp battery = 1.4 amp; 1/10 of 18 amp
battery = 1.8 amp (recommended charging rates).
7. Check during initial charging to see if electrolyte level
has fallen, and if so, fill with acid to the upper level.
After adding, charge for another hour at the same
rate.
NOTE
This is the last time that electrolyte should be added. If
the level becomes low after this point, add only distilled
water.
8. When charging is complete, install the filling plugs

firmly.
NOTE
3. Inspect the battery terminals, screws and cables for
Do not apply excessive pressure. Finger tighten only. breakage, corrosion or loose connections. Clean the
Do not over-tighten. terminals and cable ends with a wire brush and coat
terminals with Nyogel™.
9. Wash off spilled acid with water and baking soda
solution, paying particular attention that any acid is 4. Check the electrolyte level and add distilled water if
washed off the terminals. Dry the battery case. necessary.
BATTERY INSPECTION
The battery is located under the seat on the drivers side.
11
1. Inspect the battery case for obvious damage such as NOTE
cracks or leaks. Look for discoloration, warping or
Don’t add acid, use distilled water only!
raised top, which may indicate the battery has
overheated or been overcharged.
5. Check the vent tube. Make sure it’s not kinked,
pinched or otherwise obstructed.
ELECTRICAL
BATTERY REMOVAL / INSTALLATION VOLTAGE DROP TEST

See Chapter 2 “Maintenance” for battery service The Voltage Drop Test is used to test for bad
procedures. connections. When performing the test, you are testing
the amount of voltage drop through the connection. A
poor or corroded connection will appear as a high
CONVENTIONAL BATTERY TESTING voltage reading. Voltage shown on the meter when
Whenever a service complaint is related to either the testing connections should not exceed .1 VDC per
starting or charging systems, the battery should be connection or component.
checked first.
To perform the test, place the meter on DC volts and
Following are three tests which can easily be made on a place the meter leads across the connection to be tested.
battery to determine its condition: OCV Test, Specific
Gravity Test and Load Test. Voltage should not exceed
0.1 DC volts per connection
OCV - OPEN CIRCUIT VOLTAGE TEST
Battery voltage should be checked with a digital
multimeter. Readings of 12.6 volts or less require further
battery testing and charging. See the following chart.
NOTE
Lead-acid batteries should be kept at or near a full
charge as possible. Electrolyte level should be kept
between the low and full marks. If the battery is stored
or used in a partially charged condition, or with low
electrolyte levels, hard crystal sulfation will form on the
plates, reducing the efficiency and service life of the
battery.
OPEN CIRCUIT VOLTAGE

State of Charge YuMicron™ Type
100% Charged 12.70 V
75% Charged 12.50 V
50% Charged 12.20 V
25% Charged 12.0 V
0% Charged 11.9 V or less
ELECTRICAL
SPECIFIC GRAVITY TEST LOAD TEST

A tool such as a Battery Hydrometer (PN 2870836) can A battery may indicate a full charge condition in the OCV
be used to measure electrolyte strength or specific test and the specific gravity test, but still may not have
gravity. As the battery goes through the charge/ the storage capacity necessary to properly function in the
discharge cycle, the electrolyte goes from a heavy (more electrical system. For this reason, a battery capacity or
acidic) state at full charge to a light (more water) state load test should be conducted whenever poor battery
when discharged. The hydrometer can measure state of performance is encountered.
charge and differences between cells in a multi-cell
This is the best test of battery condition under starting
battery. Readings of 1.270 or greater should be observed
load. Use a load testing device that has an adjustable
in a fully charged battery. Differences of more than .025
load. Apply a load of three times the ampere-hour rating.
between the lowest and highest cell readings indicate a
need to replace the battery. At 14 seconds into the test, check battery voltage. A
good 12V battery will have at least 10.5 Volts. If the
reading is low, charge the battery and retest.
CHARGING PROCEDURE
1. Remove the battery to prevent damage from leaking
or spilled acid during charging.
2. Charge the battery with a charging output no larger
than 1/10 of the battery’s amp/hr rating. Charge at
0.1Ah for max of 15 hours. The battery is faulty if it
does not achieve a specific gravity of 1.270 after 15
hours.
3. Install battery in vehicle. Coat threads of battery bolt
with a corrosion resistant dielectric grease.
Dielectric Grease:
PN 2871329
SPECIFIC GRAVITY 4. Connect battery cables.

State of Charge* YuMicron™ Type WARNING
100% Charged 1.275 To avoid the possibility of explosion, connect positive
(+) cable first and negative (-) cable last.
75% Charged 1.225
50% Charged 1.175 5. After connecting the battery cables, install the cover
on the battery and attach the hold down strap.
25% Charged 1.135
6. Install clear battery vent tube from vehicle to battery
0% Charged 1.115 or less vent.
* At 80° F. NOTE: Subtract .01 from the specific gravity WARNING

reading at 40° F.
Vent tube must be free from obstructions and kinks and
securely installed. If not, battery gases could
accumulate and cause an explosion. Vent should be
routed away from frame and body to prevent contact
with electrolyte. Avoid skin contact with electrolyte, as
severe burns could result. If electrolyte contacts the
11
vehicle frame, corrosion will occur.
7. Route cables so they are tucked away in front and

behind battery.
OFF SEASON STORAGE

See Chapter 2 “Maintenance” for battery service
procedures.
ELECTRICAL
STARTER SYSTEM
TROUBLESHOOTING
STARTER MOTOR DOES NOT RUN
• Battery discharged - Low specific gravity
• Brake not applied
• faulty switch or switch wiring
• Loose or faulty battery cables or corroded connections
(see Voltage Drop Tests)
• Related wiring loose, disconnected, or corroded
• Poor ground connections at battery cable, starter
motor or starter solenoid (see Voltage Drop Tests)
• Faulty key switch
• Faulty starter solenoid or starter motor
• Engine problem - seized or binding (can engine be
rotated easily)
STARTER MOTOR TURNS OVER SLOWLY

• Battery discharged - low specific gravity
• Excessive circuit resistance - poor connections (see
Voltage Drop Test)
• Engine problem - seized or binding (can engine be
rotated easily)
• Faulty or worn brushes in starter motor
STARTER MOTOR TURNS - ENGINE DOES NOT

ROTATE
• Faulty starter drive
• Faulty starter drive gears or starter motor gear
• Faulty flywheel gear or loose flywheel
1. Screw the overrun clutch out to the engaged position
STARTER DRIVE on the pinion shaft assembly. Use a small piece of
Pinion Gear - Anti Kick-out Shoe, Garter Spring wire with the end bent in a hook and pick the old
Replacement spring out of its channel. Slide it off the end of the
shaft. Slide the new spring over the overrun clutch
If the garter spring is damaged, the overrun clutch may and into the spring groove. Make sure that the spring
fail to return properly. The replacement spring is (PN is positioned between the shoe alignment pins and
7042039). Use either of the following methods to remove the back flange of the anti kick-out shoes.
and install a new garter spring.
2. Remove the lock ring, end washer, spring retainers
and clutch return spring. Screw the overrun clutch off
the end of the pinion shaft. Remove the old spring
and install a new one. Lightly grease the pinion shaft
and reinstall the clutch, spring, retainers, end washer
and lock ring in the reverse order. Make sure the end
washer is positioned properly so that it will hold the
lock ring in its groove.
Polaris Premium Starter Drive Grease
PN 2871460
ELECTRICAL
STARTER SOLENOID BENCH TEST

Test the start solenoid by powering the solenoid using
battery voltage for a maximum of 5 seconds. With the
solenoid energized, there should be continuity between
terminals (A) and (B). If there is no continuity or high
resistance, replace the starter solenoid.
11
ELECTRICAL
STARTER SOLENOID OPERATION • The key switch must be turned to the “start” position to
To energize the starter solenoid the following must occur: provide 12V power via the White / Red wire.
• Once the pull-in coil is energized, the solenoid
• The brake must be applied to provide a ground path provides a current path for 12V power to reach the
via the Brown / Yellow wire. starter motor.
ELECTRICAL
STARTING SYSTEM TESTING FLOW CHART
11
ELECTRICAL
NOTES
A Wiring Diagrams
Topics Covered in this Appendix
A.1 Wiring Diagrams

Click here for Wiring Diagrams
See Operation, page 11.24for Fuse Block pin outs.
37
2015 RANGER ETX
2015 RANGER ETX
2015 RANGER 570
2015 RANGER 570
2015 RANGER 570
2015 RANGER 570
2015 RANGER 570 HD
2015 RANGER 570 HD
2015 RANGER 570 CREW
2015 RANGER 570 CREW
2015 RANGER 570 CREW W/EPS
2015 RANGER 570 CREW W/EPS
INDEX
A Operation .............................................................. 9.5

Parking Adjustment ................................................2.46
Air Box / Air Filter
Assembly View
Troubleshooting .....................................................9.44 IX
Brakes ............................................................ 2.46, 9.34
325 .................................................................. 4.11 Fluid Inspection .....................................................2.45
570 ..................................................................4.13 Hose / Fitting Inspection ..........................................2.45
Removal / Installation ..............................................4.15 Pad Inspection........................................ 2.45, 9.12, 9.29
Air Filter System Break-in...................................................... 2.5
Service ................................................................2.17 Break Even Test...................................................... 11.25
Air Intake Inspection Break-in
Engine .................................................................2.18 Brake System ......................................................... 2.5
PVT.....................................................................2.18 Engine and Drivetrain............................................... 2.5
Assembly View PVT...................................................................... 2.5
Body/Frame ..........................................................10.3 Break-In
Cargo Box .......................................................... 10.13 Vehicle.................................................................. 2.5
Dash ...................................................................10.8 Breather
Front Fenders........................................................10.8 Hose ...................................................................2.27
Hood ...................................................................10.8 Valve Inspection.....................................................2.27
Authorization
Reflash ................................................................4.51
AWD
Diagnosis .............................................................7.14 C
Operation .............................................................7.13 Cab Frame (Crew).....................................................10.6
AWD Coil................................................................. 11.7 Cab Frame (non-Crew)...............................................10.5
AWD/2WD/TURF Switch............................................. 11.5 Caliper
Front ...................................................................9.14
Front (CREW)........................................................9.21
B Rear ....................................................................9.30
Camshaft
Balance Shaft ...........................................................3.76 Bore Inspection.............................................3.47, 3.126
Installation ............................................................3.81 Chain and Guide Service ....................................... 3.127
Timing..................................................................3.81 Decompression Mechanism ................................... 3.126
Balance Shaft Installation.......................................... 3.169 Inspection....................................................3.47, 3.126
Balance Shaft Removal / Inspection .....................3.76, 3.162 Installation / Timing ........................................3.64, 3.138
Balance Shaft Timing ............................................... 3.169 Removal......................................................3.44, 3.124
Ball Joint Sprocket Inspection .......................................3.47, 3.125
Replacement.........................................................8.14 Timing - Quick Reference................................3.67, 3.141
Battery Camshaft Carrier Disassembly .....................................3.45
Charging ..............................................................2.39 Camshaft Oil Jet .......................................................3.49
Fluid Level ............................................................2.38 Cargo Box
Installation ............................................................2.39 Installation .......................................................... 10.15
Removal...............................................................2.38 Removal............................................................. 10.15
Removal/Installation ............................................. 11.30 Cargo Box Assembly View ........................................ 10.13
Service .............................................................. 11.28 Charging System..................................................... 11.25
Storage ................................................................2.39 Charging System Flow Chart ..................................... 11.27
Battery Maintenance ..................................................2.38 Circuit Breaker........................................................ 11.24
Body Assembly Views ................................................10.3 Clutch Alignment/Offset/Center Distance........................ 5.11
Body Removal ........................................................ 10.16 Clutch Chart ....................................................... 1.33, 5.3
Boot Clutch Weights .........................................................5.18
Inspection (CV) ......................................................2.36 Clutch, Starter One Way ....................................3.82, 3.171
Brake Burnishing....................................................... 9.11 Clutching
Brake Caliper Torque Specifications ............................................... 5.2
Front (CREW)........................................................9.21 Cold Weather Operation .............................................. 2.6
Brake Disc Compression Test .....................................................2.19
Front ...................................................................9.26 Conversion Table ......................................................1.34
Rear ....................................................................9.34 Coolant
Brake Pads Level Inspection .....................................................2.30
Front ...................................................................9.12 Strength and Type ..................................................2.33
Front (CREW)........................................................9.18 Coolant Drain / Radiator Removal ........................3.28, 3.105
Rear ....................................................................9.28 Cooling System.........................................................3.26
Brake Pedal Bleeding............................................................. 3.106
Replacement.......................................................... 9.9 Drain ...................................................................2.34
Brake Switch ...................................................... 9.8, 11.6 Hoses ..................................................................2.33
Brake System Maintenance .........................................................2.30
Assembly View ....................................................... 9.6 Overview ..............................................................2.30
Assembly View (CREW) ........................................... 9.7 Pressure Cap Test .........................................3.27, 3.104
Bleeding...............................................................9.10 Pressure Test ...............................................3.27, 3.103
© Copyright Polaris Industries Inc. IX.1
INDEX
Radiator ...............................................................2.34 Spider Removal .....................................................5.19

Troubleshooting ................................................... 3.175 Drive Clutch, Operation ............................................... 5.4
Cooling System Bleeding Procedure .............................3.30 Drive Clutch, Service..................................................5.16
Cooling System Diagram .......................................... 3.102 Drive Shaft
Cooling System Specifications ............................3.27, 3.103 Assembly View ......................................................7.43
CPS Replacement .....................................................4.29 Installation (front) .................................................... 7.9
Crank Case Installation (rear) ....................................................7.37
Ventilation - 325 .....................................................2.24 Removal (front) ....................................................... 7.8
Crankcase Removal (rear).......................................................7.37
Assembly ....................................................3.80, 3.167 Driven Clutch
Separation .......................................................... 3.161 Assembly .............................................................5.28
Crankcase Bearings ................................................ 3.164 Assembly View ......................................................5.26
Crankcase Breather Service ...................................... 3.160 Disassembly .........................................................5.27
Crankcase Identification .................................. 3.129, 3.146 Service ................................................................5.26
Crankcase Sealant Pattern..........................................3.23 Driven Clutch, Operation.............................................. 5.4
Crankcase, Disassembly ...................................3.72, 3.155 DTC .......................................................................4.37
Crankcase, Inspection .......................................3.79, 3.166
Crankcase, Separation ...............................................3.76
Crankshaft E
Inspection....................................................3.77, 3.163
Removal......................................................3.77, 3.163 ECT Sensor .............................................................4.35
Crankshaft Position Sensor (CPS) ECU
Overview ..............................................................4.27 ETC Learn Procedure ..................................... 4.18, 4.57
Test .....................................................................4.27 Replacement................................................. 4.17, 4.51
Current Draw - Key Off ............................................. 11.25 Service ................................................................4.16
CV Shaft Boot EFI Component Locations
Inspection.............................................................2.36 Left View ............................................................... 4.9
Cylinder Head...........................................................3.20 Right View ............................................................. 4.8
Combustion Chamber Cleaning........................3.52, 3.131 EFI Priming / Starting Procedure.................................... 4.4
Disassembly ................................................3.49, 3.128 EFI System
Inspection....................................................3.50, 3.130 Operation Overview ................................................. 4.4
Removal......................................................3.49, 3.127 Electrical
Warp ..........................................................3.51, 3.130 Break Even Test................................................... 11.25
Cylinder Head Assembly....................................3.62, 3.144 Charging System Tests.......................................... 11.25
Cylinder Head Identification .............................. 3.129, 3.146 Cooling System.................................................... 11.19
Cylinder Installation – Piston in Cylinder .........................3.60 Current Draw....................................................... 11.25
Open Circuit Voltage Test....................................... 11.30
Voltage Drop Test ................................................. 11.30
D Electronic Control Unit (ECU).......................................4.16
Electronic Throttle Body
Dash .................................................................... 10.17 Learn Procedure ............................................ 4.18, 4.57
Dash Instruments and Controls ....................................10.7 Engine
Decal Replacement ................................................. 10.19 Break-In Period.............................................3.39, 3.120
Decimal Equivalent Chart............................................1.38 Cam Chain and Guide Service ................................ 3.127
Decompression....................................................... 3.126 Cam Shaft Removal.......................................3.44, 3.124
Diagnostic Codes, Instrument Cluster .......................... 11.13 Camshaft Bore Inspection ...............................3.47, 3.126
Diagnostic Trouble Codes (ETC) ..................................4.37 Camshaft Inspection ......................................3.47, 3.126
Differential Assembly .................................................6.26 Camshaft Installation / Timing ..........................3.64, 3.138
Differential Disassembly .............................................6.24 Camshaft Sprocket Inspection..........................3.47, 3.125
Differential Solenoid................................................... 11.6 Camshaft Timing - Quick Reference ..................3.67, 3.141
Digital Wrench Combustion Chamber Cleaning........................3.52, 3.131
Communication Errors.............................................4.49 Cooling System.................................................... 3.102
ECU Reprogramming ..............................................4.51 Cylinder Head Identification ........................... 3.129, 3.146
Guided Diagnostics ................................................4.49 Cylinder Head Inspection ................................3.50, 3.130
Overview ..............................................................4.44 Cylinder Head Installation ........................................3.63
Serial Number .......................................................4.50 Cylinder Head Installation - Black Bolts ..................... 3.147
Updates ...............................................................4.46 Cylinder Head Installation - Silver Bolts ..................... 3.148
Version ................................................................4.45 Cylinder Head Removal ........................ 3.49, 3.127–3.128
Disassembly, Engine Lower End..........................3.72, 3.155 Cylinder Head Warp.......................................3.51, 3.130
Disc Inspection ................................................. 2.46, 9.34 Cylinder Honing .......................................... 3.137–3.138
Drive Belt.................................................................. 5.9 Cylinder Inspection ........................................3.55, 3.134
Drive Clutch Cylinder Installation .............................................. 3.144
Assembly .............................................................5.24 Cylinder Removal ..........................................3.55, 3.134
Assembly View ......................................................5.16 Decompression Mechanism ............................3.47, 3.126
Bushing Service .....................................................5.22 Installation ...................................................3.36, 3.117
Button to Tower Clearance .......................................5.20 Installed Gap Measurement, Piston ...................3.57, 3.136
Disassembly .........................................................5.17 Lower End Assembly .....................................3.80, 3.167
IX.2 © Copyright Polaris Industries Inc.
INDEX
Lower End Disassembly .................................3.72, 3.155 Assembly View ......................................................3.24

Lubrication Specifications .................................. 3.7, 3.89 Exhaust Valve Lash - Tappet Selection Matrix (570) ........ 3.153
Oil and Filter Change - 325 .......................................2.21 IX
Oil and Filter Change, 570........................................2.25
Oil Level - 570 .......................................................2.25 F
Oil Pressure Test.............................................. 3.7, 3.89
Piston / Connecting Rod Assembly....................3.59, 3.143 Fan Control Circuit
Piston / Rod Inspection ...................................3.56, 3.136 ,Bypass Test ....................................................... 11.19
Piston Removal.............................................3.55, 3.135 Operation ........................................................... 11.19
Piston Ring Installation ...................................3.58, 3.142 Final Drive
Piston Ring Installed Gap ................................3.57, 3.136 Torque Specifications ............................................... 7.3
Piston-to-Cylinder Clearance ...........................3.56, 3.135 Floor..............................................................10.9, 10.18
Removal......................................................3.33, 3.114 Floor (Crew) ........................................................... 10.11
Service .............................................................. 3.114 Flywheel Installation .........................................3.82, 3.171
Special Tools .........................................................3.88 Flywheel, Removal ...........................................3.72, 3.155
Specifications ........................................................3.91 Frame
Top End Assembly................................................ 3.142 Assembly View ......................................................10.3
Top End Disassembly.....................................3.43, 3.124 Assembly View (Crew) ............................................10.4
Troubleshooting ................................................... 3.174 Front Bumper ......................................................... 10.16
Valve Clearance Check / Adjustment ........................ 3.149 Front Fascia .............................................................10.8
Valve Cover Installation ..................................3.69, 3.154 Front Fenders......................................................... 10.16
Valve Cover Removal .....................................3.43, 3.124 Front Gearcase
Valve Inspection............................................3.51, 3.130 Assembly .............................................................7.18
Valve Lash - Tappet Selection ................................. 3.152 Assembly View ......................................................7.12
Valve Sealing Test .........................................3.52, 3.145 Centralized Hilliard .................................................7.12
Valve Seat Reconditioning...............................3.53, 3.132 Disassembly / Inspection .........................................7.15
Valve Spring.................................................3.49, 3.128 Disassembly / Inspection (ADC) ................................7.24
Valve Spring Removal ....................................3.49, 3.128 Exploded View (4WDC) ...........................................7.21
Engine Air Intake Inspection ........................................2.18 Installation ............................................................7.10
Engine and Drivetrain Break-in ...................................... 2.5 Operation (4WDC)..................................................7.23
Engine Antifreeze Reassembly (ADC) .................................................7.27
50/50 Extended-Life................................................2.32 Removal............................................................... 7.11
Engine Assembly Top End...........................................3.58 Front Gearcase Lubrication .........................................2.29
Engine Coolant Temperature (ECT) Sensor Front Hub ................................................................. 7.4
Overview ..............................................................4.34 Front Strut
Sensor Test...........................................................4.34 Assembly View ......................................................8.13
Engine Cooling System ..............................................3.25 Cartridge Replacement............................................8.13
Engine Detail Fuel
Cylinder Head / Crankcase .......................................3.16 Filter....................................................................2.17
Engine Detail - Torque Values / Sequences ..................... 3.11 Lines ...................................................................2.17
Engine Fastener Torque Specifications Fuel Injector
325 ..................................................................... 3.11 Overview ..............................................................4.31
570 .....................................................................3.93 Test .....................................................................4.31
Engine Lubrication............................................... 3.7, 3.89 Troubleshooting .....................................................4.33
Engine Oil Check Fuel Injector Replacement...........................................4.31
ACE ....................................................................2.20 Fuel Line
Engine Oil Flow Chart .......................................... 3.8, 3.90 Routing ................................................................4.10
Engine on Connecting Rod Fuel Pump ...............................................................4.23
Cylinder Installation – Piston Installed .........................3.59 Test .....................................................................4.22
Engine Serial Number Location ..................................... 1.3 Fuel Sender Test .......................................................4.21
Engine Service .........................................................3.33 Fuel System Troubleshooting.......................................4.58
Engine Service Specifications Fuel Tank
Engine .................................................................. 3.9 Assembly View ......................................................4.20
Engine to Transmission Coupler Service ................ 3.40, 5.13 Installation ............................................................4.21
Engine Torque Removal...............................................................4.20
Stator Cover..........................................................3.14 Fuses ................................................................... 11.24
Engine Torque Sequences ..........................................3.20
Engine / Transmission Bracket ..................................3.19
Oil Sump Cover .....................................................3.22
Stator Cover..........................................................3.21
G
Engine, Cylinder Head Assembly .........................3.62, 3.144 Gauge .................................................................... 11.9
ETC Gears
Overview ..............................................................4.18 Transmission.......................................................... 6.4
Replacement.........................................................4.18 General Information .................................................... 3.6
Test .....................................................................4.18 Ground
ETC Learn Procedure ........................................ 4.18, 4.57 Engine .................................................................2.40
Exhaust System
INDEX
H Metric Bolt Torque Specification....................................1.35

Model Number Designation .......................................... 1.2
Head Lights ........................................................... 11.16
Headlight Switch ....................................................... 11.5
Hood .................................................................... 10.17
O
Oil
I Change ................................................................2.21
Oil Flow Chart..................................................... 3.8, 3.90
Ignition Coil ............................................................ 11.20 Oil Pickup Assembly Inspection ...........................3.79, 3.166
Ignition Coil / Wire Oil Pressure Regulator (Bypass) Valve Inspection ...3.75, 3.166
Overview ..............................................................4.30 Oil Pressure Test................................................. 3.7, 3.89
Test .....................................................................4.30 Oil Pump
Ignition Coil Tests .................................................... 11.20 Assembly ....................................................3.84, 3.160
Ignition Switch .......................................................... 11.5 Oil Pump, Removal...........................................3.74, 3.158
Inner Plunging Joint / Boot Replacement ........................7.41 Open Circuit Voltage Test .......................................... 11.30
Inspection Outer CV Joint / Boot Replacement ...............................7.38
Brake Hose and Fitting ............................................2.45 Overview
Instrument Cluster ..................................................... 11.9 ETC ....................................................................4.18
Instrument Cluster, Installation ................................... 11.14
Instrument Cluster, Removal...................................... 11.14
P
K Pad
Inspection (Brakes).................................. 2.45, 9.12, 9.29
Keys, Replacement ...................................................1.20 Parking Brake
Adjustment ................................................... 2.46, 9.38
Assembly View ......................................................9.36
L Caliper Disassembly / Inspection ...............................9.39
Caliper Exploded View ............................................9.38
Leakdown Test .........................................................2.19 Caliper Installation ..................................................9.41
Lower Seat Base..................................................... 10.16 Caliper Pad Installation............................................9.40
Lubrication Caliper Removal ....................................................9.38
Front Gearcase......................................................2.29 Disc Inspection / Removal ........................................9.43
Grease Points........................................................2.10 Pad Inspection.......................................................2.47
Stabilizer Bar Pivot .................................................2.44 Pedal Position Sensor ................................................4.19
Suspension...........................................................2.44 Test .....................................................................4.19
Transmission................................................... 2.28, 6.4 Periodic Maintenance Chart.......................................... 2.7
Periodic Maintenance Chart Key.................................... 2.7
Polaris Mobile Digital Wrench (PMDW) ..........................4.45
M Power Steering Unit (EPS)
Installation ............................................................ 8.11
MAG Side Crankcase Bearing Service ......................... 3.165 Removal............................................................... 8.11
Maintenance PPS .......................................................................4.19
Battery .................................................................2.38 Replacement.........................................................4.19
Brake System ........................................................2.45 Pre-Ride / Daily Inspection ........................................... 2.6
Cooling System......................................................2.30 Pressure Cap Test ............................................3.27, 3.104
Electrical and Ignition ..............................................2.38 Propshaft
Engine .................................................................2.25 Removal...............................................................7.44
Engine Oil - 570 .....................................................2.25 Removal (CREW)...................................................7.44
Engine Oil and Filter Change, 570..............................2.25 U-Joint Service ......................................................7.44
Final Drive ............................................................2.36 PTO and MAG Side Crankcase Bearing Service ..............3.78
Fuel System and Air Intake.......................................2.17 Publication Numbers ..................................................1.18
General Vehicle Inspection .......................................2.15 PVT
Periodic Maintenance Chart....................................... 2.7 Break-in ................................................................ 2.5
Periodic Maintenance Chart Key................................. 2.7 PVT Air Intake Inspection ............................................2.18
PVT/Clutch ............................................................ 5.4 PVT System
Quick Reference Chart .................................... 2.11–2.12 Assembly .............................................................. 5.8
Service Products and Lubricants ...............................2.14 Disassembly .......................................................... 5.7
Steering ...............................................................2.41 Drive Clutch Disassembly ........................................5.17
Storage Tips..........................................................2.16 Overview ............................................................... 5.3
Transmission and Gearcases....................................2.28 Service ................................................................. 5.6
Master Cylinder Troubleshooting .....................................................5.29
Installation ............................................................. 9.8
Removal................................................................ 9.8
Master Special Tools Table ..........................................1.21
Master Torque Table ..................................................1.30
INDEX
R Engine Oil and Filter, 570 .........................................2.25

Engine Oil Pressure .......................................... 3.7, 3.89
Radiator ................................................. 2.34, 3.28, 3.104
Removal...............................................................2.34
General................................................................. 1.4 IX
Valve Seat Contact Width................................3.53, 3.132
Rear A-Arm Valve Spring.................................................3.49, 3.128
Assembly View ......................................................8.18 Valve Stem Diameter .....................................3.51, 3.130
Replacement.........................................................8.16 Valve Stem Guide I.D. ....................................3.51, 3.130
Rear Bearing Carrier ..................................................7.33 Speed Sensor .......................................................... 11.8
Rear Fenders ...........................................................10.9 Speedometer ........................................................... 11.9
Rear Fenders (Crew) ............................................... 10.11 Spring
Rear Stabilizer Bar ....................................................8.19 Adjustment ...........................................................2.44
Reflash Authorization .................................................4.51 Stabilizer Bar............................................................8.19
Relays .................................................................. 11.22 Stabilizer Bar Pivot Lubrication .....................................2.44
Replacement.................................................... 4.23, 4.26 Standard Bolt Torque Specification................................1.35
ETC ....................................................................4.18 Starter Drive........................................................... 11.32
Replacement Keys ....................................................1.20 Starter Drive, Removal ......................................3.73, 3.155
RPM Limit................................................................4.16 Starter Solenoid
Operation ........................................................... 11.34
Test ................................................................... 11.33
S Starter System
Testing Flow Chart................................................ 11.35
Seat Assembly........................................................ 10.10 Troubleshooting ................................................... 11.32
Seat Assembly (Crew).............................................. 10.12 Stator
Seat Belts .............................................................. 10.10 Tests ................................................................. 11.25
Seat Belts (Crew) .................................................... 10.12 Stator Cover / Flywheel Removal ..................................3.72
Sensor ....................................................................4.26 Stator Cover Oil Seal Inspection ...................................3.75
Speed.................................................................. 11.8 Stator Housing Removal ........................................... 3.155
Sequence Stator Installation .............................................3.84, 3.173
Torque .................................................................3.95 Stator Removal ................................................3.73, 3.157
Service Steering
Air Filter ...............................................................2.17 Assembly View ....................................................... 8.4
Service Notes Inspection.............................................................2.41
Fuel System ..........................................................4.36 Shaft, Removal (Non-EPS)........................................ 8.9
Setting TDC ........................................................... 3.122 Wheel Removal (Non-EPS) ....................................... 8.8
TDC ....................................................................3.42 Steering Assembly
Shift Cable Assembly View ..................................................8.4, 8.6
Adjustment ...........................................................2.15 Power Steering Unit Installation ................................. 8.11
Inspection....................................................... 2.15, 6.6 Power Steering Unit Removal ................................... 8.11
Inspection and Adjustment ........................................ 6.6 Steering Shaft Bearing Replacement ........................... 8.8
Shift Lever Steering Shaft Removal (EPS) ..................................8.10
Replacement.......................................................... 6.5 Steering Wheel Removal (EPS).................................8.10
Shift Weights ............................................................5.18 Steering Shaft
Shocks and Springs ...................................................8.20 Bearing Replacement............................................... 8.8
Snorkel Gear Backlash ...............................................6.28 Removal (EPS) ......................................................8.10
Solenoid. Steering Wheel
Rear Differential ..................................................... 11.6 Removal (EPS) ......................................................8.10
Spark Plug Suspension
Service - 570 .........................................................2.39 Inspection.............................................................2.44
Special Tools .......................................... 1.19, 2.4, 4.5, 6.3 Pivot Lubrication ....................................................2.44
Body/Steering/Suspension ................................. 8.3, 10.2 Spring Adjustment ..................................................2.44
Brakes .................................................................. 9.3 Switch
Electrical .............................................................. 11.3 AWD/2WD/TURF ................................................... 11.5
Engine ........................................................... 3.6, 3.88 Brake............................................................. 9.8, 11.6
Final Drive ............................................................. 7.3 Headlight.............................................................. 11.5
Master Special Tools Table .......................................1.21 Ignition................................................................. 11.5
PVT/Clutching ........................................................ 5.2
Transmission.......................................................... 6.2
Specification
Compression.........................................................2.19 T
Toe......................................................................2.42 T-MAP ....................................................................4.26
Specifications Overview ..............................................................4.26
Brake Service ......................................................... 9.3 Sensor Test...........................................................4.26
Camshaft..............................................................3.47 Tail Lights .............................................................. 11.18
Cooling System.............................................3.27, 3.103 Tap / Drill Sizes {SAE} ................................................1.36
Cylinder Head Warp.......................................3.51, 3.130 Tappet Selection Matrix
Engine .................................................................3.91 Exhaust................................................................3.71
Engine Lubrication........................... 3.7, 3.39, 3.89, 3.120 Intake ..................................................................3.70
INDEX
TDC ..................................................................... 3.122 Adjustment ..................................................3.68, 3.149

Terminal Block ........................................................ 11.28 Adjustment - DOHC ................................................2.26
Test Inspection - 325 .....................................................2.22
ETC ....................................................................4.18 Valve Lash - Tappet Selection ................................. 3.152
Thermostat Inspection / Replacement ............................3.29 Valve Clearance - Tappet Selection ............................. 3.152
Thermostat Replacement .......................................... 3.106 Valve Cover
Throttle Pedal Installation ...................................................3.69, 3.154
Inspection.............................................................2.17 Removal......................................................3.43, 3.124
Tie Rod End Inspection...............................................2.41 Valve Cover Inspection ...............................................3.43
Timing, Balance Shaft .............................................. 3.169 Valve Sealing Test ............................................3.52, 3.145
Tire Valve Seat Reconditioning..................................3.53, 3.132
Inspection.............................................................2.37 Valve Spring
Pressure ..............................................................2.37 Removal......................................................3.49, 3.128
Toe Adjustment .........................................................2.42 Vehicle Break-In Period ............................................... 2.5
Torque Vehicle Identification
Master Torque Table ...............................................1.30 Model Number Designation ....................................... 1.2
Sequence .............................................................3.95 Vehicle Identification Number........................................ 1.2
Torque Specification Vent Lines ...............................................................2.17
Crank / Balance Shaft / Cam Chain Guides ..................3.17 VIN ......................................................................... 1.2
Piston / Crank / Balance Shaft ................................. 3.101 VIN Location ............................................................. 1.3
Wheel and Hub ......................................................2.36 Voltage Drop Test .................................................... 11.30
Torque Specifications
Body/Steering/Suspension ................................. 8.2, 10.2
Brakes .................................................................. 9.3 W
Cam / Cam Chain / Cam Chain Tensioner....................3.15
Cam / Head / Flywheel / Stator Cover ................. 3.97, 3.99 Water Pump
Clutching ............................................................... 5.2 Mechanical Seal / Oil Seal...................................... 3.108
Crankcase / Timing Chain / Oil Pickup.........................3.96 Removal / Installation ............................................ 3.107
Cylinder / Oil Filter / Oil Pump ...................................3.97 Water Pump Service ..................................................3.31
Engine / Transmission Bracket ..................................3.18 Wheel
Engine Mounting .................................................. 3.121 Installation ............................................................2.37
Final Drive ............................................................. 7.3 Removal...............................................................2.36
Spark Plug / Starter / Throttle Body / Valve Cover ......... 3.13, Wheel Alignment .......................................................2.42
3.100
Transmission.......................................................... 6.2
Transmission Mounting............................................. 6.4
Transmission
Assembly View ......................................................6.36
Differential Assembly ..............................................6.26
Differential Disassembly ..........................................6.24
Disassembly .........................................................6.19
Gears ................................................................... 6.4
Installation ............................................................6.15
Output Shaft Backlash.............................................6.28
Removal...............................................................6.10
Removal - 325 ........................................................ 6.7
Service ................................................................6.18
Troubleshooting .....................................................6.35
Transmission Lubrication ...................................... 2.28, 6.4
Trouble Codes
Instrument Cluster (DTC) .........................................4.37
Troubleshooting
Brake Noise ........................................................... 9.4
Brake System ........................................................9.44
Clutching ..............................................................5.29
Cooling System.............................................3.87, 3.175
Engine ........................................................3.86, 3.174
Engine / Cooling System ..........................................3.86
Front Gearcase (ADC).............................................7.30
Fuel Injector ..........................................................4.33
Starter System..................................................... 11.32
Transmission.........................................................6.35
V
Valve Clearance

RGR 570 Ext Crew 2015-2016

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RGR 570 Ext Crew 2015-2016

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2015 - 2016 RANGER ETX / 570 2-SEAT

2015 - 2016 RANGER 570 CREW

Publication Printed October 2015 (PN 9926806 R03)

NOTE provides key information by clarifying instructions.

Loctite, Registered Trademark of the Loctite Corporation

Nyogel, Trademark of Wm. F. Nye Co.

Fluke, Registered Trademark of John Fluke Mfg. Co.

Mity-Vac, Registered Trademark of Neward Enterprises, Inc.

Torx, Registered Trademark of Textron

Hilliard, Trademark of the Hilliard Corporation

Warn, Trademark of Warn Industries

FOX, Registered Trademark of FOX RACING SHOX

RydeFX, Registered Trademark of ArvinMeritor

REVISION INDEX: 2015 - 2016 RANGER 4X4

REV DATE CHANGES

R03 06/10/2016 Parking Brake Service Added

CHAPTER 1: GENERAL INFORMATION

VEHICLE IDENTIFICATION NUMBER (VIN) DESIGNATION (2015+)

VEHICLE DESCRIPTORS VEHICLE IDENTIFIERS

VIN / ENGINE NUMBER LOCATION

2015 RANGER ETX ELECTRICAL

MODEL: 2015 RANGER 570

2015 RANGER 570 ELECTRICAL

MODEL: 2015 RANGER 570 CREW

CATEGORY DIMENSION / CAPACITY

2015 RANGER 570 CREW ELECTRICAL

Headlights 2 single beam Front Tire Model / Size AT489 / 25 x 8 R12

MODEL: 2016 RANGER ETX

2016 RANGER ETX ELECTRICAL

MODEL: 2016 RANGER 570 4X4

2016 RANGER 570 4X4 ELECTRICAL

MODEL: 2016 RANGER 570 2X4 (INTL.)

2016 RANGER 2X4 (INTL.) ELECTRICAL

MODEL: 2016 RANGER 570 CREW

CATEGORY DIMENSION / CAPACITY

2016 RANGER 570 CREW ENGINE

ENGINE STEERING / SUSPENSION

MISC. SPECIFICATIONS AND CHARTS

2016 RANGER 570 (Intl.) R16RMA57N1,

SERIES# PART NUMBER

MASTER SPECIAL TOOLS TABLE

ENGINE / COOLING SYSTEM

Water Pump Seal Puller

ENGINE / COOLING SYSTEM

Laptop or Desktop Computer USB/

Rear Output Seal Driver Snorkel Tool Transmission Nut Socket

Roller Pin Removal Tool

MASTER TORQUE TABLE

ITEM TORQUE ITEM TORQUE

Power Steering Bracket to TPS Mounting Screws 18 in-lbs (2 Nm)

Starter Power Wire Nut 54 in-lbs (6 Nm) 9 ft-lbs (12 Nm)

pounds (lb) x 0.454 = kg

cubic centimeters (cc) x 0.061 = cubic inches

STANDARD BOLT TORQUE SPECIFICATION

1/4-20 5 (7) 8 (11) 12 (16)

1/4-28 6 (8) 10 (14) 14 (19)

5/16-18 11 (15) 17 (23) 25 (35)

5/16-24 12 (16) 19 (26) 29 (40)

3/8-16 20 (27) 30 (40) 45 (62)

3/8-24 23 (32) 35 (48) 50 (69)

7/16-14 30 (40) 50 (69) 70 (97)

7/16-20 35 (48) 55 (76) 80 (110)

1/2-13 50 (69) 75 (104) 110 (152)